Tm 5-5090 GENERATOR SET, BUDA

7/28/2019 Tm 5-5090 GENERATOR SET, BUDA

http://slidepdf.com/reader/full/tm-5-5090-generator-set-buda 1/362

BLE,DIESELENGINEDRIVEN

HASE,60-CYCLEOR230/400

,BUDAMODEL6-DTG-317.

T

NIA

P u b l

i c D o m a i n , G o o g l e - d i g i t i z e d

/ h t t p : / / w w w . h

a t h i t r u s t . o r g / a c c e s s_

u s e # p d - g o o g l e



ManualandPartsCatalog,

ieselEngineDriven,published

edfor theinformationand

.

C),June10,1941.)

fWar:

ff.

P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

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ind


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OFTHE

ENERATORSET

vaDiesel6-DTG-317

rheadvalves,fourcycle,six

.M.,laboratorytest

8",Stroke5-1/8"

cu.in.

tionforstartingand running

elFuelSpecifications,

wingfanend

aseOilCapacity-6quarts

-24-1/3quarts

er-CenturyElectricTypeARC444,

%powerfactor,3phase,50/60

cycle,230/400voltsat50

ns.BuiltbyCenturyElectric

ouri.BudapartNo.DP-2493.

t-GeneralElectricCompany,Buda

facturerModelNo.

onaldsonCompany,Inc.B-954

Union,Inc.25H97


/ h t t p : / / w w w . h





t'd.)

roductsCorp.

G.B.OilClarifier,Inc.

ericanBoschCo.

Mass.

AmericanBoschCo.

rod.

G.B.OilClarifier,Inc.

27

28

8


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7-is

ments13

andRecom-

17-22

enerator24-42 23-38

tor4339

4640

on4741. 42

on4842 -43

ation4943. 44

eration5045

ation51 45

ation5245


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http://slidepdf.com/reader/full/tm-5-5090-generator-set-buda 8/362 P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

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0KW,Diesel-poweredACGeneratorSets

50 and60cycles.Theseunitsare

perationwithanotherunit ofthe

maingeneratorat60 cycles(1800r.p.m.)

0KW;at50 cycles(1500r.p.m.)de-

W.Thegeneratoris drivenbyaBuda-

peengine.SeeFigure1.

esessentialtotheoperationof

torare containedinthecontrolunit.

Theoveralllengthofthe Buda6-DTG

5/16",width251/8",andthenet

eFigure12 whichgivesthedetailsfor

mensions.

NE

ovaDieselengineisofthefour

lidinjectiontype.Thecylinders

ntend,and thedirectionofrotation

deris1-5-3-6-2^1.TheBuda-

vesoftandquietcombustionbecauseof

inciple.

orStartingMotor

Model6-DTG-317,


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PERATION

da-LanovaDieselengine,wehave

akingplaceas inanyfour-stroke

engine,asfollows:(SeeFigure3.)

ke,

reatedbyrapidlycompressing

ufficientlysmallareatoraise

ointwhereitwillcausecombustion

ravity,haswhatisknownas

nthefueloilis raisedtoacer-

iteand burn.Intheprocessof

d.

eethat whenthepistonstarts

ke(a),the inletvalveisopen,thus

air intothecylinderthroughthe

pistonreachesthe bottomofthe

derisfilled withairandthe piston

compressionstroke(b),allthevalves

roke


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srapidlycompressedtoa final

rokeofapproximately1/12theinitial

olumecausesanincreaseinpressure

aseintemperaturetobetween900° and

ngthecompressionstroke,the

combustionchamberunderapressure

squareinch.As alreadymentioned,

peratureat whichtheywillignite,

belowthetemperatureofthecom-

stionchamber,thefuelinitsfinely

esuponcomingincontactwiththis

sgeneratedwhichexpandsthe

gthepistondownwardonthepowerstroke

ofthispowerstroke,the exhaust

pistonstarts upwardontheexhaust

rnedgases,thuscompletingthe

VALOWPRESSURECOMBUSTIONSYSTEMOPERATES

ustionchamber,theclearancevol-

sistsofthree chambers.Themaincham-

eight,whichalso formsthehousing

valves.SeeFigure4. Thetwoauxil-

ell,islocateddirectlyopposite


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D.Re-

chil-

Period,

pressed

alsoforced

he

energy

rand

edpor-

to

gycells

t

op-

sbeing

ough

tothe

ffuel

passes

themain

otethatno

da

fuel

reit is

nrush-

al

Main

erethecom-

lythetem-

The

wly

ughly

ayed

nexplo-

leshock

c.,an

ENCE

where

the

gh

kly,and

tout

NCEacrossthemaincombustionchamber

st

ksup thecloudoffuelin

ontofthe cellandstartsthe

oubleSwirl"inthemaincom-

-bustionchamber.


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dturbulence,thoroughlymixes

mainchamberandresults incom-

fuelconsumption.

burnsveryslowlyinthe main

oroughlymixedwiththeair,the

elandpossible shocktothepistons,

nated,bythe actionoftheenergy

eatureoftheBuda-LanovaDiesel

FTHEENGINE

engine,therearecertaincom-

ytokeeptheengine runningproperly.

e providedsoallnecessaryaction

instant,thereforeatimingsystem

eacontinuousflowof fuel,hence

stbea lubricatingsystemandalso

hwillstoreenergyforstarting the

automaticcontrolsasthesafetyen-

esolenoidorsafetyshut offvalve,

e oilpressureistoo loworthe

ginemust notbeallowedtoover-

a coolingsystem.

ettingthecamshaftgearwith

epistonsareattachedthatthe cam-

valvesfor eachcylinderintheir

tepnecessaryinafourstrokecycle

ttheright time.Thefuelinjection

ginesothatit willinjectthefuel

mbustion.

epares,andcontrolstheflowof

isgravityfedfromthe fueltank

Thefuel passesfirstthroughthe

el transferpump,thentothe

ughthesolenoid,orsafetyshut

onpump,fromwhichit isin-

nlinesandfinallythroughthe noz-

amber.Thefuelreturnline car-

veredby thetransferpump,through

njectionpump,and returnsitto

rates theflowofthefuel oil.

eflowoffuel,a singlespeedgov-

atesthespeedoftheengine.The

teofoperationatan evenpacefor

set.Figure10 showsthepositionof

tothefuel injectionpump.Itcannot

hatextremecarewithregardto clean-

handlingthe fuel.Seethethird

mmandments",ChapterII.


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em,theenginewouldnotrun

dbyfrictionwoulddestroythe en-

sTern-in thecrankcaseandto

ertoII-theoil filter-From

emain Salleryline>

cationSystem


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eliveredtotheconnectingrodbearings

kshaft.Thepistonpinsreceivetheir

connectingrods.Thecylinders

nfromthe connectingrodbearings.

depassagesleadto thecamshaft

deliveredtotheidlergear hub

ar shaft.Oilfromthehubof this

drilled holesandispickedupby a

earswhereitpassesthroughsmall

earteeth, sprayingtheentiregear

ionsuppliesoilforthelubrication

mpressionignitionengineneed-

ombustiblegases,theelectrical

marilytosupplyenergyforcranking

uch electricalcontrolsasthesafe-

noid (safetyshutoff)valve.The

ansof thestartingmotorwhichre-

yfromthestoragebatteries.These

bya12 voltgeneratorincombination

hichautomaticallydecreasesorin-

flowingto thebatteriesdepending

eeengine wiringdiagram,Figure7.

gram


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sofftheexcessheatfromthe

mperaturethatmakesforefficient

tsocontrolstheflowofthe water

ool,thewaterre-circulatesaround

ithoutpassingthroughtheradiator.

e thermostatopensandallowsthe

theradiator.Thewateris circu-

pthroughthe waterjacketandradi-

esplace.Afancreatesa draft

lthe water.Awatertemperature

eratureofthewater.Anautomatic

o thatifthewatertemperature

ewill beautomaticallystopped.

DEXCITER

neratorisofthe revolvingfield,

g(ballbearing)type,havinga

withthebackendofthearmatureshaft

ctiontotheengineflywheelthrougha

ng.Thegeneratorisameansby

yischangedintoelectricalenergy.

ebearing(ballbearing)type

haftsupportedinsideabored hole

rshaft.Thesetwoshaftsare

druffkeyandaninternal keyway.

generator,thecurrentofwhich

emaingeneratorfields sothat

whichcanbecutbythe armature

rebyinducingthealternatingcurrent,

cessaryforpowerorlight.

todeliver ratedloadcon-

temperatureriseof40° Centigrade.

machinecanbe reconnectedtooper-

esbychangingthelink connections

ox.

ficienciesareasfollows:

areself-cooled,theexciter

edtotheshaftofthe armature.A

vecouplingcoolsthealternator.


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TROLUNIT

heinstrumentsandswitches

ngineandthegenerator.Thecon-

steelframewitha controlpanel

blesidesandback,a fixedtop

ttom.Theunit issupportedatthe

cushionstoreducethevibrationfrom

stotheexternalequipmentaremade

SeeFigure13.The Controlunitis

ricManufacturingCompany.Formethod

t,seeChapterIV, Paragraphs28


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ANDMENTS"

mmandments"fortheoperatorsof

ratorsets,ifpracticed,willnotonly

gine,thegeneratorandcontrol

atorfromminorandmajortroubles

canbepreventedbythesimplepre-

hese"TenCommandments".

orset.Readthis operator's

edirections.

gineanditsaccessories,

atorandthecontrolunit,clean.An

eanshismachinediscoversmajor

usedmerelybyloosefastenersor

ions.

an.Wateranddirtin thefuel

serviceinterruptionsthanany other

hextremecare.Strainthefuel

wateranddirt. Donotdependen-

er.Theuseofa funnelequipped

is themostsatisfactoryinsurance

nteringthefueloil tank.Useonly

ecificationsasgivenin para-

with cleanwaterorsuitable

sload,keepthewatertemperature

raddwatertoanoverheatedengine,

ithoutwater inthecoolingsystem.

mmendedviscosityandchange

hours.

wly.Neverracea coldengine.

the recommendedspeedrange.

ginewearis duetoabrasivedust

tandreplenishthe oilintheair

oftenasrecommended.

emaingenerator.Mostgener-

fover-lubrication.Lubricatethe

yasoftenas isrecommended.See

omrainandsnow.Moisture

tionandwindingsofthe generator.

m theoutdoorsforinsideoperation,

otectingtheunit untilithasac-

Thuscondensationispreventedfrom

nallyonthegenerator.


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LEDIESEL

DLUBRICANTSTOBEUSED

EMPERATURE

cationandService

UnitsandParts

below0° F.,refertoEFSBL-1000-D.

above90F.,referto EFSBL-1000-E.

catedarefornormalservice.Forextreme

st,changecrankcaseoilandlubricate

ours,orevery4 hoursinextremely

drefilloilcupto circularlevelmarkwith

ependingonoperatingconditionsre-

lean,cleanairintakepipe,and re-

ontight.

whenengineisthoroughlywarm.Re-

ee Table.CAUTION:Whenrunning

ageindicatesoil iscirculating.Forsevere

AE50maybeused.(CrankcaseandFuel

.Every64hours,removebreathercap,

edforengine inspectionorrepair,

pscreen.CAUTION:Ifoilpressuredrops


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ONSAND

TION(LUBRICATIONCHART)

rtheBuda-LanovaDieselengine,

beconsidered:(1)It isimport-

as asufficientbodytoproperly

ngersandvalves,sincetheseobtain

uelitself.Improperlubrication

kingplungersand valves.(2)The

ughtoflowfreelyatthe prevailing

mustbefree fromwateranddirt.

Dieselengine troublethananyother

crackedresidual,ablend,ora

dingit comeswithinthescopeof

ns:

salat100° F35-40

e

3

enttoobtainagoodgrade

portancethateveryprecaution

nhandling.Besurethat thecon-

ediment,andwater.Filter ele-

egularlyandreplacedatgiveninter-

aphs69and 70.

COMMENDATIONSFORTHEENGINE

taltoefficientengineper-

oncernsshouldbelubrication.The

edto becomeanemiceitherfromthe

ofthe wrongkindofoil.Thefol-

nsforthegradesof crankcaseoil

geoftemperatureindicated.


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EMPERATURE

inesoperatinginhightemperaturesand

nsforlongperiodsof timeconsumemore

evelshouldbecheckedandcrankcase

annormally.IfOE(S.A.E.50)is

waysbesure tobringoillevel to

RefertoEFSBL-1000-E).

doorswherethe temperature

n ifoperatedoutdoorswherethe

ower,judgmentshouldbeusedin se-

theindooroperation.

,theenginecrankcaseshould

eday'soperation.Beforethestart

,theoil shouldbeheatedto180°

the crankcase.Nospecialprepar-

eratingthe maingeneratorincold

ommendedforthemaingeneratorare

lowzerotemperatures.(Referto

BRICATION

terareshippedfrom thefactory

dgradeof greaseinthebearings

oximately4,096hoursofoperation

tures.Atthe endof4,090hoursof

uldbereplaced.

ASEFORALTERNATORANDEXCITER

llbearings;

urpose,No.2.

aring,No.3, heavyAity.


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ARINGHOUSINGGREASECAPACITIES

8"longand 1/8"indiameter

oneounce.Thiscanbeusedas aguide

aryandwhenagreasecup ofknown

PERATURES

dgreasesareonthebasisofactual

er194° F.(90° C.).Jfoperatingand

chthatthebearingtemperaturesex-

greaseshouldbechangedmorefre-

commended:

eevery2048hours.

ASEFROMMAINGENERATORANDADDINGNEWGREASE

orbearingand housinggrease,

.10,over2 ounces)inthehousing

fewminutestoallowtheoil tothin

edrainplugand drainasmuchaspos-

e

this

ec-

un

o

t

he

a-

n

-

y.

ase

ean.

ssFigure8.LocationofMain

,GeneratorGreasePlug

ndthrowgreaseinside thegenerator.

thusthrownfindits waytothecol-

itwillseriouslyaffectthe operation

vencausecompletefailure.

reasegunsshouldbeavoided

eisnoaccuratemethodofde-

easebeingintroducedintothe bear-


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eof greasecups,itissuggested

un with-astraightnozzlebeused.

eamountofgreaseexpelledperturn

ouldbe ascertained.Ifagrease

vailable,thiscanbescrewedinto

teadofagreasegun.

ASEFROMEXCITERBEARINGHOUSING

ofthefull sealedtype,re-

nttreatmentinremovingtheoldgrease

main generatororalternatorunder

ghasnodrain.Therefore,the

ovedandthegreasewashedfromthe

ithcleanunleadedgasolineorkerosene.

outtheballbearing.Afterthe

letelyfillthebracketcavitywith

atorsettobe lubricated,the

andperiodsoflubrication,a complete

tpage.

citerRemovedfor

y2,048hours.


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ine ShowingLocationof

ump

temployshigh

rousandmaybe

eratingpersonnel.

pmentalways

ouchingit.


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SET

TNGTHEGENERATORSET

30KW,Diesel-poweredgeneratorsets

nspectedbeforeleavingthefac-

diatoraredrainedforshipment.

ratorsetinto operation,orone

drained,certainstepsarenecessary

ydamagethatmighthaveoccurred

e.SeeChapterVII,paragraph115

storedfor anylengthoftimeor

yprolongedperiod.Partofthe

ringunpacking.

broughtfromcoldsurround-

shouldbekeptcovereduntilits tem-

temperatureso astopreventcon-

andotherparts.

TORSET

k,andbatterywaterare shipped

oxes.Eachis markedastocon-

BoxedforShipmentwithOne


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ATORSET

et,firstremovethethree cover

.CAUTION:Thetophasthe muf-

re 11.Afterthetopis removed,

hen thesides.Removethepipes,

oolkit,andsparepartswhichare

th thegeneratorset.Thegener-

kidwithsixcarriagebolts.Re-

generatorsetofftheskids.Re-

erfromthegenerator.

RATORSET

ll inspectionofthegener-

loose electricalandhosecon-

dcapscrews;seethattheair clean-

dirt canbesuckedinbecauseof

gesbetweenthetubes of.the

eyarefreefromanydirt orforeign

heflowof airbetweentheradi-

aroundtheflywheelhousingand

re nolooseboltsin thecoupling.

foreignobjectsareinsidethegen-

toseethatit turnsfreely.

elof thecontrolunitand

tionsandseethat-allfuses arein

EGENERATORSET

torsetshould besuchthat

moistureboth beforeandafter

romleakingpipes,rain,snow,or

mosphereshouldbeexcluded.Itis

eepthewindingsdry,sincemoisture

anceandincreasesthelikelihood

chine'slocationislevel.Fig-

nsionaldrawingofthegeneratorset.

ANDCONTROLS

dicatetheefficiencyofthe

functionsareawatertemperaturegauge,

anammeter,anoil pressuregauge,

ure13.

uge

ugeindicatesthetemperatureof

oreoperatingtheengineunder aload,


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ebetween100° to120°.Forcontinuous

reshouldnotbeallowedto gobelow

ratureshouldnotexceed200"F.If

ceeds205° F.,theunitwillautomat-

.

eindicatesthetemperatureofthe

rpropergradeandlevel ofoilas

temperatureexceeds250F.

Panel


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cateswhetherornot theproper

ubricatesatisfactorilytheinternal

eing delivered.Theoilpressure

o35 poundsundernormaloperating

erecommendedviscosity.

ops below7pounds,theunit

wn.

peratingbecausetheoil pres-

oundsor thewatertemperatureex-

ecauseoftheshut downandcorrect

ndoillevel,andtemperature,before

nit.

stinguishedfromthemaingener-

herateofchargeordischargetaking

Thereadingsare from0to+3O,

nd0to-30,whichindicatesdischarge.

atoronthegeneratorcontrolsthe

onforthereadingtobeat 0orclose

tthebatteryis fullychargedor

fhighreadingcontinues(over

with thevoltageregulator.How-

willtakeahigher rateofchargefor

showshighonthedischarge,there

weentheammeterandthegenerator.

umentbywhichtheengine speed,

te(R.P.M.)ofthe crankshaftare

60cycleoperationunderfullload,

0R.P.M.If itfailstocomeup to

noverloadoraloss ofenginepower,

governorisoutof adjustment,in

rthe-dropinR.P.M.shouldbedeter-

eengineare:safetyenginecon-

ntrol,andstarterbutton.

witch

switchprotectstheunitin

eorhighenginetemperature.In

o functionproperly,theopera'ting

rowpointingtotheleftfor start-

estartsandtheoil pressureregisters

uldturn automaticallyinthedown-

mitthe switchtostoptheengine

woilpressureor highwatertem-


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OPERATION

temperatureofthecontracting

atelythesame.)

disconnectoneunitfrom

ratinginparallelwithotherunits,

kerisfirst openedbeforeattempt-

heengine.

sprovidedonthegovernor

vernorleverwhenthe stopbuttonis

provisionismadeinorderto

ris openwhentheengineisstopped.

ostat,andAmmeterSwitch

edfor controllingvoltage,

ermitsreadingallphasesof theload

aseshouldnot exceedthenameplate

iterfield rheostatshouldalways

on themark.

usedwhenitis necessaryto

aralleloperation.Theprocedure

main generatorcontrolsandinstru-

phs34 and35underOperationofthe

OROPERATION

ecommendedgradeoflubri-

eratingtemperature,tothelevelin-

uge,ordip stick.SeeLubrication

ansoftwaterorasuitable

batteriesin seriesandcon-

t. SeetheWiringDiagram,Fig-

esarefilledwithelectrolyte.The

houldbeconnectedtothegroundon

negativeterminalsshouldbe connected

gneticswitchmountedunderthecontrol

lineto thefirststagefil-

dthesuctionconnectiononthe

onconnectiononthefueltank

s thepipeextendingtothe bottom

ne,from thefuelinjection

e15),tothefuel tankreturnopening.

openingshouldbe connectedto

"T" providedinoneofthe fuel

icaloutletofthis"T"shouldbe pro-

onforvent purposes.


/ h t t p : / / w w w . h





ofthe fuelinjectionpump

valvespringtensionsopumphousing

efuelreturnconnectionatthefuel

e15)andworkthe handplungeronthe

eair bubblesceasecomingoutof

ming


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SET

obtoonposition,thatis, point-

afetystopcontrolismountedatthe

ththecontrolpanel.SeeFigure16.

ntrolmarked"stop"isposi-

on.

d continuesfiring,release

enginewillautomaticallycomeup

M.(60cycleoperation).Assoon

rsontheoilpressure gauge,the

ocatedbelowtheswitchboardcab-

allyinthedownwardposition.This

htostopthe engineincaseoffail-

orhigh watertemperature.

peratureiscold,it willbede-

±goperatedat

dforapproxi-

eengineandmakethe necessaryelec-

makeconnectionwithgeneratorrunning.

toryareconnectedforGOcycle

CONNECTIONS

onnections,refertotheWiring

amisattachedtothe insideofthe

coverandisalsoshownin Figure17

eloadto terminalsmarked1,2,3,

TORSET

cuitbreakeris inoffposi-

utlinedinparagraph32andper-

tonormalno-loadspeedofapprox-

atedonthetachometer.


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ofGeneratorSetand ControlPanel


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SET

atorknobforapproximately

atedonthe voltmeter.

ostatso thatthepointer

rontofthepanel.See Figure13.

perateunderload.Withthe load

erintothe"on"position.

onnectedtotheexternalcircuit,

astheload isapplied.Theammeter

nedtoeachof itsthreepositionsto

ase.If singlephaseloadsarecon-

adjustedin orderthateachphase

ble.Thisswitchshouldbe leftin

highercurrent.

ldnotbecalleduponto deliver

ton onephaseeventhoughtheother

.

dedwithasafetyswitchlock

oardcabinet.Thisswitchprotects

ressureor highenginetempera-

permitthe switchtofunctionproper-

ned withthearrowpointingto

onastheenginestarts andoil

auge,theknob shouldbeturnedin

iswillpermittheswitchto stop

reduetolowoil pressureorhigh

esignedforparalleloperation

metypeandmodel.Whenparallel

entwogeneratorsets,itis neces-

ized.Forthispurpose,eachunit

glampsandasynchronizingswitch.

twounits tobeparalleledmustbe

alleloperationtothe samebus.

tiepoints1to 1,2to2, etc.The

estarted asdescribedinpara-

nectedtoload.Thesecondgenera-

tospeedanditsvoltageadjusted.

econsideredastherunningmachine

oming.Besurebeforestartingthe

tthat thebreakerisin"off"posi-

el,thesynchronizingswitchshould

onatwhichtimethe synchronizing

honandoffat afrequencydependent

speedbetweentheunits.

edwhenthefrequencyofthese

andthe lampsareoutordark.When

hetwounits maybeconnectedby


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a t h i t r u s t . o r g / a c c e s s_ u s e # p d - g o o g l e



SET

stingSc

ut.

akerandinstallthespare50 A.

mountedontheright sideofthecon-

MOVINGTRIPPINGELEMENTOFAIRCIRCUITBREAKER

ateonpanel.Removethefour

coverandremovecover.Thenre-

evicebythetwoholdingscrewsand

totheright.it willhangbyits

thebreaker.Removethethreelead

ablecontactsofthebreaker.Re-

nghandle.Thenraisethetrip ele-

ngagetheelementfromthebreaker

nedtoa rightsidecoverand,

theunusedelementshouldbebolted

ebreakerfromtheunit,

tedattheback,theundervoltage

thdrawnfromtheirclips,andthe

whichremovethefourrearholding

akerfromitssupports.

vablehandle,careshouldbetaken

tion"lineisatthe bottomorthe

dle,is rightsideup.

thefront coverofthebreakers

ytightenedto avoidstrains.It

progressivelytightenedasonewould

arwheel.Thesteelcoveronthe

edto giveanequalclearancebe-

oss beforetightening.


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SET

0CYCLETO50CYCLEOPERATION

60cycleto50 cycleoperation

ontheterminalbox located

terminalboardinlinewith

tachedtothe terminalbox,orsee

over'fromthevoltageregulator.

inalonthe smallresistoratthe

o positionmarked50cycles.

romtheswitchboardcabinet

mas aguide,reconnectwiresmarked

itionas showninthemarginalin-

onisgivenattheupper righthand

m,Figure17).

ngtothe instructionsin

tainthatthecircuitbreakerisi n

eadjustingscrewat the

ownin Figure18.Loosenthis

ratesatapproximately1500r.p.m.

et shouldnowbereadytooper-

volts.Allcoversshouldbe replaced

BEOBSERVEDDURINGOPERATIONS

ecleansingfluidonoraround

peration.Asparkfromthema-

echangesintheconnections

noperation.Alwaysstopthegen-

onchangesaretobemade.

newithrags,etc.,whileit

hmaybecomecaughtina rotating

ury totheoperatoranddamage

sarytopolishthe collector

emachineshouldfirstbestoppedso

ervethesafestposition forthehands

hbothcollectorringsatonce

ay becomeimbeddedinthesandpaper,

ridgeacrossthetwocollectorrings.

eeparagraph91.


/ h t t p : / / w w w . h




SET

CONTROLUNIT

egeneratortohand con-

rmallysuppliedby thevoltage

orisrunning,turn theexciterfield

oltagebeginstofall.Thevolt-

nshouldbeturned toincreasethe

regulatorisoutof circuitand

ledbytheexciterfield rheostat

rcontrol,turn thevoltagead-

ytoitsnormal positionandmove

slowlybackto itsnormalsetting.

ulatorwillagain operateinits

ORMERS

saresinglesecondarytrans-

owith5 Amp.secondary.Thecom-

sa24:1ratiowith5 Amp.mid-tap

ercurrentforcompensationatboth

dAattheterminalboard iscon-

n 60cycleoperationandthemid-


/ h t t p : / / w w w . h




NERATOR

ncyofthisBuda6-DTG-317gen-

thattheoperatorinspect,lubricate,

set atregularintervals.Regularityin

almaintenancewilleliminatethede-

bleandunnecessarydelays.

stinctionismadebetweenthe

s,andminorrepairswhichthe operatorcan

rm,andsuchmajorrepairsandoverhauls

bythemaintenancemenormechanicswho

equipment,andspecialdata.Such

themaintenancemanualforthis

orrepairswhichiswithinthe scope

eratorMaintenance.Themaintenance

data,andskill iscalledmaintenance

ionsmayvary,itissomewhatdiffi-

sastothe timeintervalswhenlubri-

ncebedone.However,thefollowing

o do,andwhen,canbefollowedunder

tions.

makeadjustmentsorrepairs,de-

ingare giveninChapterVIunderthe

eor generatorneedingsuchadjustment

NTNEEDEDBYTHEOPERATOR

BudaModel6-DTG-317generator

thefollowingtools:

0"

7/16x1/2

9/16x5/8

3/4x13/16

ead).. Sizes15/16x1"


/ h t t p : / / w w w . h




uldbe

rkero-

graph

Be

per-

use

itis

om-

tno

ssed

nder

er,

PERATION

aintenancerecommendations.

kcasewiththerecommendedoil.

tofthecrankcasewhiletheengine


/ h t t p : / / w w w . h





ment.SeeFigure48.

vernorandinthe fuelinjection

21.

artingmotorwithafewdrops of

ssively.

thebatteries.NOTE:In

ddwateraftershuttingdownoperation.

ofoperationstoavoidfreezing.

nd cablesleadingtotheinstru-

ropsof oilalongthesurfaceof the

ontrolandwithyourfingers,flexthe

oilto penetratethroughthewire.

rwith

nt-

ase-

tor.

uld

as

OTE:

at

OPER-

erarm

clear-

arm

ot

he

Fig-

attery

estartermotor


/ h t t p : / / w w w . h





EY

onofFanBeltby Shifting

ectorsshouldbea partoftheregular

anremovetheinjectorstobeserviced

adysoserviced.Methodsforsuchser-

intenancemanualforthisengine.

gs,excitercommutator,and

ator.Thebrushesshould beinspected

ssure,andfreedomin theholders.The

dbeinspectedfordirtandoil onbrush

owbars,carbondepositsinthe under-

utatoringoodconditionwillhaveahigh-

showalight browncolor.Seeparagraph

collectorrings,should beinspec-

edcondition.

dsecondaryfuelfilters.


/ h t t p : / / w w w . h





OFOPERATION

operationmaintenance.

enginebywashingwithkerosene,

t.If thedirtisthick,allowto

washoffthe dirtwithhoseandwater.

hout anysludgeandcleantheoil

ecttheinsideofthe engine,checking

theconnectingrodsandmainbear-

onnectingrodbolts,nuts,andmain

ht.Checktheoilsuctionscreenfloat

acetheoilpangasket.

andardflushing compound.

esandall electricwiring.Re-

oakedwireswithnewones ofthesame

OFOPERATION

essoriesshouldbecompletelyover-

erepair.

gine accessoriesareundergoing

torandexcitershouldbeinspected.

conditionsaresuchthat the

eeds194°F.(90°C.)thegreaseshouldbe

18,19,21,and22.

theoverhauloftheengine and

enerator,andthecontrolunitare

Manual,SectionII.

OFOPERATION

xcitershouldbelubricatedaccord-

nin Paragraphs18,19,21and22.


/ h t t p : / / w w w . h





STMENTS

USTMENTSANDREPAIRS

rV,thereare certainadjustments

atormustperform.Theseservicings

ntenance.Thischaptergivesthe

ctionsforcarryingouttheseserv-

onaldescriptionoftheunits.

tionsforthoseservicingswhichcome

ratorare given.Completeengine

structionsaregivenintheMainten-

stheoperatormayhavetocheck,

alphabetically.

akeminoradjustmentsandre-

ph44ofthepreviouschapter.

TION

leanerto preventabrasive

seof enginewear,fromentering

is oftheoilbath type.The

terelementbeforeitentersthe

eengine.Inordertoremovethe dirt

mustbeproperlyserviced.

PCONNECTION

heaircleanerandtheintakemani-

atall times.Becauseofnormal

pshouldbecheckeddailyorevery

.

P

ptiedandcleaned,andrefilled

dwithengineoil daily,every

gure19 onPage41.Ifdust con-

ad,itmaybewise tocleanthe

every4hours.Checkthefelt

o theintakemanifoldadaptorevery

orcleaning.

MENT

ssemblyshouldbe soakedin

han aircompressorevery64operat-


/ h t t p : / / w w w . h





STMENTS

sareexceptionallybad,thisserv-

8 hours,oroftenerifindicatedas

electricalenergyusedto operate

plycurrentto thepanellight.The

nginecharginggenerator.

CINGTHEBATTERY

eelectrolytetogetbelow

Useonlycleandistilledwaterfor

herthanjustbelowthebottom

egassingwill causetheelectrolyte

d tothewaterasthis willgive

onditionofthebattery.Keepthe

ftheyshow atendencytocor-

yathin coatofvaselinetoprotect

Theoutsideof thebatterymustbe

electrolytethatmaybeonthe metal

ratedwithammoniaora bicarbonate

dof bakingsodatoonegallonof

wateranddry thoroughly.

eachcellwitha hydrometer.

85indicatesapproximatelyfullycharged,

ed,and1.150indicatesdead.Never

ddingwaterforthereadingwill

ndition,thisgassingis most

.Therefore,thevoltageregulator

maintenancerepaircrewforfaulty

theMaintenanceManual.Ifoneor

uiremorewaterthanothers,it is

dcellwhichshouldbe checkedby

TION:Donotallowthe batteryto

.It willbecomeruinedbysul-

E

cold weathertotestthespe-

ezesbetweenthetemperaturesof

elowzero,dependingonthestateof

teraftershuttingdownforthenight,

kly.Alwaysseethatit getsa

.


/ h t t p : / / w w w . h





STMENTS

MENTPANEL)

e

ONOF

t-

ic

nt,

d

h,allofwhichcontrolthegenera-

e27.Theenginecontrolsandin-

eraturegauge,oiltemperaturegauge,

ge,tachometer,enginestopcontrol,

stopswitch.

ONOFTHEINTERIOREQUIPMENT

urrenttransformersforthe

enttransformerforthevoltageregu-

nalboardsforthemainandsecon-

fuses.SeeFigure26.Thespare

ntforthecircuitbreakeris mounted

iselementisusedfor50 cycle

gramfortheunitis locatedonthe

nthismanual,Figure17..

ON

sdesignedto controlthethree

orwhichmaybeoperatedateitherof

PM.,127/220V

PM.,230/400V

oltageismadeby movingcon-

alboardof thegeneratorandon

heunit, andbychangingtheposi-

istormountedinsidethe voltage


/ h t t p : / / w w w . h





STMENTS

espeedmustbeadjustedseparately

redoperation.Inaddition,the

entinstalledinthe circuitbreaker

tbechangedto thespare50Ampere

cycleoperationisdesired.Thepro-

rfor60cycleor 50cycleorfor

inparagraphs39,38, and35.

TION

,waterpump,andthegenera-

crankshaft.Thereshouldbeapprox-

ebelt atitsfreestposition.

TENSION

tcanbeadjustedbymovingthe

thelocknuton theadjustable

ndmovethegeneratorin thedirec-

e propertensionisobtained,

gure25on Page44.

T

fanbelt,alwaysloosenthe fan

lowthebelttobe slippedinplace

voidanyinternaldamagetothe

TION

317engineisequippedwithtwoftiel

and asecondaryfuelfilter.

Becausefueloilsarelessfinethan

regum,fineabrasives,andwater.

eringtheengineand therecausetrouble,

tageoffueloil filtrationisused.

sbe servicedasrecommended,but

houldbeinspectedandreplacedif

he fuellineisbreakingdownin-

accident.Thisinternalbreak-

articlesintothefuel stream.


/ h t t p : / / w w w . h





STMENTS

irVent

ARY

ug

e

e

-

)

TION


/ h t t p : / / w w w . h





STMENTS

tor


/ h t t p : / / w w w . h





STMENTS

edinthefollowingsteps:

FROMENGINE

nganylines,applykeroseneor

ctionsinorderthatdirtand grease

ubingandleak-offlines (See

overtheiropenendswith clothor

entranceofdirt. Removetheholding

yfromtheengine.Becarefulnotto

eagainstanyhardsurface.Ifthe

kbecauseofcarbondepositswithinthe

orcanberemovedasshownin Figure

gtopreventdirt fromentering.

torLines


/ h t t p : / / w w w . h





STMENTS

-

actionis bymeansofacontrolroa

r.Inordertoobtain continuedlong-

nto thefuelinjectionpump,in-

nofthis finemechanism.Theopera-

propertoolsandequipmentandnec-

dnotattempttoservicethefuelin-

ervicesofwhichheis capable,

tedfuelinjectionpumpdifficulties

maintenancerepairasoutlinedinthe

ctionII).

erator'sattentionthatthe

ontributingtolongandtrouble-free

onpumpisproperfiltrationof the

ratorshouldfollowtothe letter

ervicingtheprimaryandsecondary

hs68to70.

EINJECTIONPUMP

tionpumphousing(camshaft

aysbefilledwithagoodgradeof en-


/ h t t p : / / w w w . h





STMENTS

ction

mpandGovernor

perlevelof whichcanbedeter-

gaugerod.Thepumpplungersdonot

cethisis inherentlycontainedin

Theoilgaugerod isprovided

the highestpermissablelevelof

isrepresentedbythe endofthe

il showsuponit,swithdrawalfrom

elis toolowandmustbe broughtup

nreached.Theoilisfilled in-

ghthe oilfillerandbreather,as

helubricatingoilinthe pump

ineoilischanged-atevery64hours

his,removethedrainplug which

ONPUMP

tarted,theinjectionpump

of airbylooseningthefuelr e-

pofthe housingasshowninFigure15.

TIONPUMP

umpwith theengine,thefol-

y:

to timethefuelinjectionpump


/ h t t p : / / w w w . h





STMENTS

ion

s

hole

is

hat

st

ve

ems

-

romthecapscrewsofthefuel

thethreecapscrewssothatthe

eFigure36.

lerPipe


/ h t t p : / / w w w . h





STMENTS

thepumphousingimmediately

b.Theoneis verticalandindicates

pump.Theotheristothe leftof

8ofa turnandindicatesportclos-

einjection.SeeFigure37.This

he gearhubtiminghole.If neces-

tilthistimingmarkis inthecenter

umpis nowinroughtimewiththe

rews.

rate,removetheNo.1 injection

ump.RemovetheNo.1checkvalve

thefuel injectionpumpandreplace

outthecheckvalve.SeeFigure38.

heelbackward1/2turn(turn

ggears).Atthisposition,the

the No.1angleconnectionbyoper-

hefueltransferpump.

n thedirectionofrotation

tethehandprimerof thefueltrans-

theopenconnectionseepsslowly.

wninFigure39,blowgentlythe fuel

eningastheengineis beingslowly

erbeingoperated.Byblowingthe

momentwhentheseepagestopscanbe

efuelseepagestops,the cranking

timing markNo.1F.P.I,observed


/ h t t p : / / w w w . h





STMENTS

ckValve

geAway(TimingInjectionPump)


/ h t t p : / / w w w . h





STMENTS

theflywheelhousing.Thismark

nterofthehole.SeeFigure34. If

vancedorretarded.Ifthetiming

arkNo.1F.P.I,is approachingthe

singtiminghole.If retarded,the

etimingis retarded,loosen

huband turnthehubclockwise(as

gree mark.Iftimingisadvanced,

rnedcounter-clockwiseonedegreemark.

ubcounter-clockwise,asshown

nthehubretainingnut.ExertJust

enchhandletomovethe hub.Tighten

kthetimingbeginningwithStep6.

eatthe foregoingproceduremorethan

g.

diatelyuponportclosingwhich

dcenterofNo. 1cylinder,asmeas-

arkedNo.1 F.P.I.

ging)

eneratorchangesmechanicalenergyinto

ourceof electricityforsupplying

ngine andfortheotherengineacces-

sourceofelectricity,butonlya

ure41.

arginggeneratorframeisa combi-

voltageregulatorunit.Thecircuit

itchthatclosesandopensthe circuit

dthestoragebattery.Thecircuit

eryfromdischargingbackthroughthe

espeedfallsbelowtherequired speed

ebattery.Thevoltageregulatorre-

twhenthemaximumisnot needed,thus

batteries.Theoperatoriscautioned


/ h t t p : / / w w w . h





STMENTS

y adjustmentstothevoltageregulator

eequipmentnorthenecessarydata

orservicingsotherthancleaningthe

th.SeeFigure42.

UTATORANDBRUSHES

ectthecommutatorandbrushes

ocheckforhighmica(insulation

perbarsofthecommutator)orfor the

ound.Visuallyinspectallthewiring

egulator,fromthe regulatortothe

erytothe groundforwornorfrayed

ndforlooseorcorrodedconnections.

r discolored,itcanbecleaned

00sandpaperagainstitwhilethe arma-

the sandoutofthegeneratorafter

.Ifthecommutatorisroughorworn,

movedandcompletelyoverhauled.See

eelyin theirholdersandshould

commutatorsegments.Ifthebrushes

tofalignment,oilsoakedorwornto

inallength,whichis 7/8",the

d.

HES

rnbrushes,lift thebrusharm

eadasillustrated,and installthenew

rtainthatthe brushisputin sothat

shmatchesthe curveofthecommu-

ttobesurethat thebrushedgeis

gGov-

or

H


/ h t t p : / / w w w . h





STMENTS

nt

ntrolsofvoltageregulator

using No.00sandpaper.

hecommutator.Withtheabrasiveside

brushatitsproper springtension,

rdordownward,makingcertainthatthe

beingsanded.Donotsandexcess-

breaktheedgeofthe brush.See


/ h t t p : / / w w w . h





USTMENTS

RINGTEKSION

thethirdbrusharmnear theend

othe faceofthebrush.Takethe

avesthebrush.Thethirdbrush spring

0ounces.Withthemainbrushes,hook

nthe lipofthemainbrush armand

efaceof thebrushlThemainbrush

ouncesmaximum.

ATOR

hould begiventhreetofive

the oilerinthetop oftheend

tatorendoilpocketwithengineoil

ilandoverflowholein thecommuta-

ure41.

ORFUSE

edin thebaseofthevoltage

re44.It isafiveamperefuse and

shouldbereplacedbyoneof the

isheldinplace byathumbscrew.

PTION

overnoris tomaintainwithina

denginespeedwiththe normalidling

eedrange,irrespectiveoftheengineload.

ontrolstheengine idlingspeedto

aximumspeedtopreventracing.The

unit, rigidlymountedtooneend

The governorisinternallyconnected

ol rod.SeeFigure33.


/ h t t p : / / w w w . h





STMENTS

VERNOR

uldbefilledwith engineoilup

ycasting.SeeFigure33. Theoil

64operatinghourswhenthe fuelin-

seoilischanged.

EED

W.Setthegovernorto1800R.P.M.by

ngscrewshowninFigure18 onpage36.

gcircuitbreakerto"Off"position.The

nthetachometershouldbe1845R.P.M.Ifnot,

ndturnthe surgeadjustingscrew1-1/2

speedisover1845- andturnout

5.Againapplyloadandset thespeed

Figure 18onPage36.Againdisconnect

erfor1845R.P.M.NOTE:Itmaybeneces-

gprocedureseveraltimesto obtainexact

orparalleloperation.Installthe lid.

XCITER

ngthegenerator,thenecessary

lconnectionsforloadingthegenera-

swillaid theoperatorarealready

riodsof servicingsforwhichthe

givenin ChapterV.

ation,keepingtheexcitercommu-

hspringtension,cleaningtheslip

atingnewbrushes.Thefollowing

servicingscanbebest accomplished.

bricatingthegeneratorisalready

ubrication,paragraph17,themethod

edhere.

edoutthat therearecertain

ervedwhileservicingthemaingenera-

follows:

ecleansingfluids,whilesetis

newhileitisrunning.To polish

mmutator,themachineshouldbefirst

tormayobservethe safestposition

hbothcollectorringsatonce,

ecomeimbeddedinthe sandpaper,

ridgeacrossthetwocollectorrings.


/ h t t p : / / w w w . h





STMENTS

RNATORRINGS,EXCITERCOMMUTATOR,AND

ectedforwear,properspring

heholders.If thebrushesarestuck

ubstances,theyshouldberemoved

sandinsulatingsupportsshouldbe

igtailconnectionsshouldalwaysbe

withCommutatorcoverplateremoved.

houldbeinspectedforroughness

shouldbe smoothedinaccordance

inparagraph91.Badlyroughened

trued inalathe.Thisbecomesan

ancerepairasoutlinedin theMain-

I.

einspectedfordirtandoil onthe

ghorlowbars,carbondepositsin the

eFigure45.Acommutatoringood

yglazedappearanceandshowa light

nisconducivetolongcommutator

notbedisturbedotherthanto clean

non-lintingcloth.Ifcommutatoris

d,itshouldbepolishedwith #00sand-

Theremedyforhigh orlowbarsis to

a lathe.Thisisan operationfor

linedintheMaintenanceManual,Sec-


/ h t t p : / / w w w . h





STMENTS

ENERATORANDEXCITER

tershouldbe keptascleanas

ndexternally.Accumulationsofoil

witharagslightlydampenedwithgas-

all partsarecleanedanddriedbefore

oiddangeroffire.Againit isempha-

r keroseneinoraroundthemachine

ceasparkfromthecollectorrings

thecleansingfluid.

ternatorand exciterclean,pre-

ycompressedair.Makecertainthat

pressedairlines.Alsoairof extreme

d1'ir thispurpose,sincetherewould

ulationanddamagingthewindings.

poundsshouldnotbeusedin blowing

eratedin extremelydirtyatmos-

donemoreoftenthanindicatedin the

windingsbecomecakedwith

s,thatcannotbe removedwithair,

edisassembledandthewindingsthor-

hdampenedwithgasoline.Thewind-

driedbeforereassembly.Thisbecomes

ncerepairasoutlinedin theMaintenance

THINGTHEEXCITERCOMMUTATOR

waysbekeptcleanandwell-polished

non-lintingmaterial.Novaselineor

dbe usedonthecommutator.

esrough,theroughnessmaybere-

mmutatorwithapieceofsandstonefrom

sbeencuthavingthe sameradiusasthe

oneisnoteasilyobtainable,#00sand-

sing itagainstthesurfaceofthe com-

edlikethesandstone.In bothcases,

erunatthe highestenginespeedduring

vingtheroughness,thesandstoneor

edbackandforthalongthe surfaceparal-

ginerunningatits highestengine

thebrushesare raisedfromthecom-

ontoavoidunnecessarybrushwear

vebecomingimbeddedinthesurface

movedfromtheundercuttinggrooves

ardwoodshapedtothe widthofthe

aper.Alsosuitableforthisoperation

defromwhichthesethasbeenground

awblade,however,exercisecareto

mutator.Afterthecommutatorhasbeen


/ h t t p : / / w w w . h





STMENTS

orandbrushfacesshouldbecarefully

twhichmightcutor scratchthecommu-

THSHOULDNEVERBEUSEDONA COMMUTATOR

NGS

htherings,all thebrushes

unnecessarybrushwearandtoprevent

ecomingimbeddedinthesurfacesof

sbe keptcleanandwellpolished

non-lintingmaterial.SeeFigure46.

escriptionshouldbeusedonthe rings

sbecomeroughorpitted,therings

ishingwitha pieceofsandstonefrom

sbeencuthavingthe sameradiusasthe

vailable,thensandpapermaybeused

faceofthe slipringswitha block

ndstonementionedpreviously.SeeFig-

machineshouldberunat itshighest

process.Ifthe ringsarebadly

sesandpaperorsandstoneshouldbe

pwitha finergradeofsandpaperfor

sis done,theringsandbrush

ycleanedinorderto removeanygrit

torscratchthe sliprings.

RINGTENSION

rspringsare designedtogivea

Thispressureisnot criticalonthe


/ h t t p : / / w w w . h





STMENTS

prings withapieceofsandpaper

wood.

essurewillbemaintainedindefinite-

circuitopensandpermitsthebrush

current.Ifthisoccurs,thenthe

andshouldbereplaced.Theexciter

gnedtogiveapressureof 10to13

ealternatorbrushholder spring,

nsionindefinitelyunlessthebrush

rmitsthebrush holderspringto

cursand thespringpressurefalls

gsshouldbe replaced..

re,hookasmall springscale

ximately1to2 poundsunderthebrush

hereitbearsonthe brush.Pullthe

edirectionof thebrushtravelin

nthe fingerisjustlifted offthe

bemade.

TINGBRUSHES

eexciteroralternatorareworn

nallength,theyshouldbereplaced.

ewbrushes,thebrushshouldbe

normalbrushspringtension.Drawa

er,withthesandedsideagainstthe

tation followingthecontourofthe

ealternatorslipring.


/ h t t p : / / w w w . h





STMENTS

ryclothontheslip rings,the

es.

donewith#0or#00sandpaper.

minutesand inspectthebrushcontact

g.Ifnotperfectlyseated,repeat

th#0or#00 sandpaper.

mportantthatthebrushesor both

bereplacedwiththe sametypeand

hemanufacturer.

TION

etallicand carbonparticles

stonsurfaces,andremovesthesludge

lt ofcondensation,andbyfiltering

neswithcrankcasegases,thefilter

eration,from5%to10% oftheoil

oilfilter,throughitsbuilt-in

sinto afilterbasewherewater,

rticlessettleout.Fromhere,it is

filteringcartridgewherethecotton

clesand absorbfineforeignparti-

sthetop outletandissent backto

ilFilterElement.


/ h t t p : / / w w w . h





STMENTS

gs

ofOilFloatAssembly.

ilpumpdeliversfrom50 to100$more

ke,the pressureisseldomaffected

etravelsthroughthe filtermany

RELEMENT

blybyturningthehandleatthe top

wise-.Removethedrainplugtodrain

mpandto breakthevacuumcreated

nt.Pullthedirtyelementout bythe

* Flushoutthefilterhousingwith

ementevery128hoursand replacethe

vergasketwithanew one.Withfil-

,checkforleakagebyrunningtheengine

OTE:Donotremovethefilterelement

vingtheoilin thecrankcase.Leave

ewashingfilterbodywithkerosene.

TION

screenarrangedto riseand

crankcasesothatonly thebest

s-thusavoidingthesludgeandfoan

ebearingdamage.SeeFigure49.


/ h t t p : / / w w w . h





STMENTS

T

ved,checkthejointaboutwhichthe

mustbefreeofanybinding.A

or adamagedcastinginwhichthefloat

ngatthat point.Thedamagedparts

thetubecannotberemovedfromthe

ntireunitmustbe replacedifthetube

TSCREEN

ved,examinethescreenand,if

ovingthefloatandwashingit ingaso-

owthecompressedairthroughthe

articularlybad,bendout theears

yingparticularattentiontothe posi-

encanthenbethoroughlycleaned

eldshouldbecarefullypositioned

verthe bodyflange.Clinchtheears

TION

eradiatortubesby thefancools

ngthroughthetubes.The hotwater

oolingas itgoesdownward,andleaves

outlet,to enterthewaterpumpandbe

ngine.NOTE:Theuseofhardwater

theenginewaterjacketsandinthe

ndingtoclogthecirculation.Where

notbeavoided,useacommercialwater

ATOR

andflushit.Examinethe

tegration.Someanti-freezesolutions

herubberhose connectionstodeter-

bberpassinto thesystemandob-

Ifthesystemis clogged,attacha

radiatoratthewateroutlet connection

dsofwater pressure.Thisreverses

arrythedirtor particleswhichhave

bes,backupwardand outthroughthe

e radiatortooverflowthroughthe

y.Iftheradiatoris sobadlyclogged

otserveto freethecirculation,then

etaken:

ATOR

tofmuriaticacidtothree parts

itytofill theradiator,orasolu-


/ h t t p : / / w w w . h





STMENTS

ourpoundsofcommerciallyeaddedto

ertofill thecoolingsystem,allow

stand inthesystemforthree orfour

ndthoroughlyflushthe coolingsy-

OR

dsolderor radiatorcompoundsto

oclogtheradiatortubes.Aleaky

dbysolderingin theregularmanner.

cerepair.

RPTION

epushrods,whichinturn operate

bearingdirectlyonthe endsofthe

vestoopenandclose.The rockerarras

sof adjustingthevalvessothatthey

y.

ARMCLEARANCE

ethat,atalltimes,thereis the

cebetweentherockerarmsandvalve

beoperatingveryslowlybutat

enthecheckismade.Theintakeclearance

haust.012".Insert thecorrectfeeler

erarmandthevalvestem.SeeFigure 23.

ugebackandforth.If theclearance

notethat thereisjusta slight

whichmomentarilypreventshimfrom

ftheclearanceis notcorrect,this

sswhichwill notpermitthefeeler

onsiderabledrag.Ontheother hand,

withoutanybinding,the clearanceis

ARM(TAPPET)CLEARANCE

hownin Figure23onpage43,

nthe adjustingscrewineitherdirec-

djustmentthatis needed.Tightenthe

iththefeelergaugeasoutlined inthe

cessary,repeattheadjustingopera-

mentis made.

ARMLUBRICATIONANDWEAR

clearance,checktherockerarms

Thereshouldbeaseepageofoil


/ h t t p : / / w w w . h





STMENTS

arms.Alsocheckthewearon the

ctsthevalvestems.If undulyworn,

maintenancerepairwhoshouldreplace

L

ntrolisdesignedfor usewithDiesel

ginesagainstoilpressure failureor

.SeeFigure16onPage32.The control

ctedtothesolenoidfuellineshut-off

whichclosesthefuel linevalveand

aseoflowoilpressureor highcooling

ontrolhasbeensetatthe factory.

necessarytore-set.Howeverthe

egiven intheMaintenanceManual.

maintenancerepairpersonnelbecause

eededtomaketheadjustments.

n,thecauseoffailure mustbe

eisagainstartedand allowedtooper-

ofautomaticshut-downduetoover-

temperaturemustdropapproximately35°

e-started.NOTE:Undernocircum-

oraddcoldwaterto anOverheatedengine

dbeseriouslydamaged.

ankstheenginewhenthe starting

etweenthestoragebatteryandthe

Bendixdriveengagesthestarter mo-

elwhenthe motorrevolvesanddisen-

rts.Whentheengine starts,theBendix

thanthesleeveoftheBendixand

ongthethreads,thusautomatically

heflywheel.

ATORANDBRUSHES

ndinspectthecommutator.Ifthe

olored,itcanbe cleanedbyholding

peragainstitwhilethearmatureturns.

motoraftercleaningthecommutator.If

rworn,the startingmotorshouldbe

andoverhauled.

eelyin theirholdersandmake

tator.Makesurethebrushesare per-

mutatorsegments.Ifthebrushhold-

ushesareworn tolessthanonehalf

otorshouldbe removedforanover-

epairasoutlinedin theMaintenance


/ h t t p : / / w w w . h





STMENTS

thewiringinsidethe motoraround

g fromthebatterytotheground,

tingswitch,andfromtheswitchto

rodedconnectionsandforfrayedin-

ERMOTOR

engineoiltothe oilerinthe

regularperiodsrecommendedinChapter


/ h t t p : / / w w w . h





STORAGE

gyCellCoverPlates.

NERATORFORSTORAGE

facesshouldbe slushedwitha

edbeforeshipmentorstorageto pre-

ristobestored foranylengthof

orust shouldbeinspectedperiodi-

y30daystoseethatrustinghas not

ushpartsifrequired.The maingen-

witha water-proofpaper.NOTE:If

eheatingsystemshould beprovided

he generatorfromalternatefreez-

cheaterwitha thermostaticcontrol

chequipmentisavailable.

erplates.SeeFigure51.

lugsandpourone ounceofrustpreven-

hencranktheengineoverwiththe

lopen forafulltwenty-five

energycellplugsandtightendown

hendrainthecrankcaseandalso

mthe injectionpump.Fillthe

ntofthefuelinjectionpumpwiththe

re.Replacethebreatherandfiller

thebottomofthebreatherof thefuel

pethevent holeinthetop ofthehand

ump.

coverandpaintthe rockerarm

swiththerust preventative.Replace

dandreplacethe aircleaner.

dfor storageorshipment.

batteriesandstorethemsepar-

vailable,foran unusedorstoredbat-

edoncea month.Ifthebatteryis

hargedstate,itwillberuined by


/ h t t p : / / w w w . h





VICE

ATORSETFORSERVICEAFTERALONG

ror theenginewaspreparedfor

foregoingparagraphs,thefollowing

cethembackin service.

tivemixturefromtheentire

ctionlinesto thenozzlesbydiscon-

dsecondaryfuelfilters.

compartmentoftheinjection

oper gradeoflubricatingoil.

ealedup theventandbreather

mtheair intakemanifold,andexhaust

sandpreparetheengine for

ph32, ChapterIV,afterthefollow-

emaingeneratorthathavebeen

ventrusting.

dexciterball bearings.If

sbecomeoxidized,thebearingsand

washedoutthoroughlywithcleangaso-

earingsandhousingsrefilledwiththe

ofgrease.Seeparagraphs21 and22.

gsandcommutator.Ifthese

ebrushesshould beraisedinthe

ctorringsand thecommutatorpol-

.

Makesure thattheymovefreely

generatorshouldberun atnoload

utesin ordertodetermineifthe

mallybeforeapplyingload.


/ h t t p : / / w w w . h





toooften thatover90%ofengine

bygoodperiodicallubrication,inspec-

alreadyoutlinedinthis manual.The

dinsodoing isonlyafractionof what

ubletiesup theoperatorandhisopera-

esometimesdonottakethe stepsthat

eveloping,andsometimestrouble

our own.

ssible,thetroubles thatmay

ymptoms,causesandremediesis

notwithin thescopeoftheoperator,

ansthattheengineor themain

tionofthemaintenanceshopwhichhas

nddataasoutlined intheMain-

I.

osections.Thefirstchartap-

andthesecondchartapplies tothe

olunits.

or

-

er-

o

ve.

ys-

k,

p.

ex-


/ h t t p : / / w w w . h





HART(Continued)

Also

ror

gs,

s,

d

h

ns.

umpasa

o

op

-

for

In-

for

-

-

o

e

ris


/ h t t p : / / w w w . h





HART(Continued)

should

cere-

w

r.

ance

ance

gs

wash

pressure

e-

pump.

main-

ance

ance


/ h t t p : / / w w w . h





HART(Continued)

ance

ed

ance.

asa

o

er-

ain-

-

m.See

y main-

main-

n

Sec-

ations,


/ h t t p : / / w w w . h





HART(Continued)

ecanbe dividedInto

chcannotbedirectly

ocess.

eitherfrom loose

el,improperlyadjusted

-byduetosticking

causedbytooearly

e speedandloadon

e totoogreatanad-

propertimingof the

herthanfuelknocks

undingthe knocksout

tionsandbycuttingout

enthe looseorIncor-

d,theremedyIs

ncetoarticlesunder

willbe foundhelpful

ections.Becausethese

ebyanexperiencedme-

dreportanyofthe men-

aintenancerepair.

kingor wornnozzle,

es,stuckorworn

nders.Checkthein-

ranceandmakesurethat

theguide.Checkfor

tresort,assumethe

ectionpump.Ifthe

omesajobforthe


/ h t t p : / / w w w . h





LECHART

air.

air.

air.

gs.

air.

air.

gs.

n-

ers

e

air.

ease


/ h t t p : / / w w w . h





LECHART(ConI'd)

r.

eFig.

n-

ers

e

air.

free

ushes

air.

air.

air.


/ h t t p : / / w w w . h





LECHART(Cont'd)

s

on.

air.

air.

air.

utator

.See

nel

e

air.


/ h t t p : / / w w w . h





/ h t t p : / / w w w . h





sfortheinformationandguidanfl

personnelinoverhaulingtheBuda6-Dfl

ratorsetanditsaccessories.SeeFl

ceinstructionsaretheresultofactm

andincludespecifications,tolerances

eassembly,inspectionandrepair,test!

eededforthe overhaul,andafewhint

andrepairaresuchservicing

movalof theenginefromthemachin

inChapterVIII.Recommendedlubr

heretolubricatetogetherwit

ubricationandmaintenancearegiven

ctionI.Instructionsfororderir

sManual,SectionIII.


/ h t t p : / / w w w . h





,Toolsand

s,Tabulated

sions,Capa-

ratorSet

rSet)1-2114-116

nspectionof

................4117-134

mentofEngineParts51 35

.....6135

Bushings,Sleeves.7-11135-138

.......12-14138-140

onnectingRod

..15-18141-143

,RockerArms

.....19-32144-148

Housing........33-34149

...35-37150-151

•.........38-39152-153

..............40-42153- 155

..............43156-1 83

nspectionof

msandtheir

...........45174

FuelTransfer

6-49174-179

dNozzleHolder)50-63 180- 186

....64-691 86-193

.......70-72 193

......73193 -194

m.................74194-195

VoltageRegulator75-91195-206

.........92-114206- 219

.............115-119219-223

............120223

.121223-224

....122-125224-225

....126-128 225-226

226

00-E


/ h t t p : / / w w w . h





................130226 -227

..........131-132228

...133-136228-231

e.............137231

ndService

torandExciter138-150232-238

dReassemblyand

..............151-161238-247

rouble............162-166 247-250

................167250-252

ataandVarnish

.....168-176253-257

eofControl

...............178-186258- 262

strumentSwitches.187-189262-264

witchboard........190264-266

..........190264- 266

...............191266

t.............192266

...........193266-268

Operation.......194268

...........195268

mentofAirCir-

...196268- 269

ycleto50

......197269

...........198269

Set,Testsand

...............199270

GeneratorSetAfter

......200-201270-271

ts— Tappetsand

201-202273- 275

erhauls

erSubmersionin

203276

ofGenerator.......204276-277

............205277

..............'206277

..........207277

...........208-212277- 279

CTION


/ h t t p : / / w w w . h





30KWDIESELGENERATORSET

AirCell

mmeter

39152-53

Connect-

1

gs38..152

amshaft

hings11.137-38

8142-43

Rods15141

17141

87262

58

erior

eration

elEqulp-

Unit

186262

82260

183261

tem120223

dand

135

r14140

ar13138-40

38

ketsFor

orTube

Cylinder

rArm

6... 147

ndSeats

es9137

Generator

277


/ h t t p : / / w w w . h





dCollec-

mbly

y153..241

Data

47

nsion

torand

8236

enerator

Brush

ure142..233

Rings,

Brushes

ousing

3

on139..232

s164..248

Servicing

0232

es155.242

sand

mMain

w

156243

atal73.255

shes

8

Wind-

orCoils

nces....1O9

70193

Filters

uel

nspec-

176-79

a47.176

ump

m45174

a47....176 P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

/ h t t p : / / w w w . h





3

Diesel

ITCH

rting

99210

dStart-

nd

heSole-

112217

19

ng

Replacing

28

228

LVE

Oil

...231

230

3228

OilPump

DAND

ycleto

9

91266

eration

8

92266

6-67

Tripping

ker

69

iston

Re-

4

6225

or128.226

tor127.225-26

very128

-7

99210

tor92..206

otor101.210

uled

endix


/ h t t p : / / w w w . h





TEDDATAONTHE

ENERATORSET

G-317.

valves,fourcycle,sixcylinders.

eengine.

tartingandrunning.

perkilowatthourunderfullload.

ystemtoallcrankshaftbearings,

pistonpins,valverockerarms,and

ofcamshaft.

dby-passvalve.Thirtytoforty

ependentuponspeed.

GS

ticallyanddynamically;Tocco

gsurfaces;drilledforpressure

inbearings-7.

m)1-1/2"

m)1-1/16"

m)1-1/16"

m)2"

m)1-1/16"

m)1-1/16"

m)2-1/8"

N


/ h t t p : / / w w w . h





,precisiontypebearings.Number

Diameterbolts- 9/16".

attreatedandcarefullybalanced

ssurelubricationofpiston

er,9-1/2".Numberofcapbolts-

lcapbolts-chromenickelsteel.

siontype,steelback.Diameter-

41.3mm)1-5/8".

DRCASTING

einonecasting,chromenickeliron.

gidityandpermanentalignment

nkcasebreathingthroughinletport

ther.

e,easilyremovedorreplacedinthe

on,ground finish.

ated,hardenedandground,integral

type,bronze,pressurelubricated.

34.9mm)1-3/8"

22.2mm)7/8"

22.2mm)7/8"

7.0mm)1-1/16"

ation-forcefeed.Numberof

Operatedbypushrodsandrocker

r-2.Diametereffectiveinlet-

Material-Inlet- Chromenickel

usteniticsteel.

eplaceableexhaustvalveinserts.

menickelsteel.Numberperhead-

ofrings-5.Width ofrings-com-

trolrings,3/16".

0"


/ h t t p : / / w w w . h





bearing,total-2-29/32"..Rill

o35° Baumegravity.SeeFuel

r'sManual.

positivemechanical(solid)in-

gthofstroke.Amountoffuel

rautomaticallycontrolledbygov-

Numberpercylinder-1.Hori-

pistonhead,doesnot strike

silyremovedforinspection.

uarts

arts

XCITER

M.Freq.PhaseVoltsAmps.

3127/22098.5)

4045.1)

eraturerating:Open,50° C.-

lation.

mps.Winding

t1256 Shunt

peraturerating:Open,50° C.,

tricCompanyMachineSpec.No.6971.

ficienciesareasfollows:

areself-cooled,theexciterby

the shaftofthearmature.The

ON


/ h t t p : / / w w w . h





vecouplingcoolsthealternator.

ElectricCompany,St.Louis,Missouri.

ES

erbearinghousinggreasecapacities-

ces

s

-OO

-4804D

97 P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

/ h t t p : / / w w w . h





7PermElectricSwitchCo.1501

28PermElectricSwitchCo.6500

8ElectricAuto-LiteCo.MBR-1003

ase)... 2,995pounds

0"

75"

nches

e

)

e:

rol

rance:

learance:

ce:


/ h t t p : / / w w w . h





009.015

.007.015

035.005

p).005.008

e

005

t)

ng:

ge

sing

bottomcenter

opcenter

opdeadcenter

tomcenter

ANCES

chthatendplayis centralizedin

tthe rotorcanbemoved.0625"

0!


/ h t t p : / / w w w . h





HVALUES

hepoundstensionrequired.to

pscrewsofthediametershown.

FORCOMPLETEOVERHAUL

ecessaryforthecompleteoverhaul

ingtheengine,engineaccessories,

egiveninthefollowinglisting.

ithanasteriskarefurnishedwith

7/16",1/2",9/16",19/32",

16",7/8",15/16",1".

andle

widthblade.•

7/16"- 1/2",1/2"-9/16",

8",5/8"- 3/4",*3/4"-13/16",

d10".

es,*8",'HO",and12".

eratorset.

ON


/ h t t p : / / w w w . h




and8"

eadhammer1#

4"-12 oz.

/2or2#

shouldincludepunch,*l/8"point

diameterpointand6-1/2"pin

2,.003,.004,.005,.006,.008,

5,.020,.025inch.

eratorset.


/ h t t p : / / w w w . h




OR

OR

"andone 5/16"alienwrenches,

ULLER*

n,fordiameterof 2-3/4".

witharmsat least8"longbeneath

ningofatleast5".Arms should

gtospecificationsinFigure298.

3"to4".

eratorset.


/ h t t p : / / w w w . h




NDHONES

ER

es

eratorset.


/ h t t p : / / w w w . h




ENERATORSET

overhaulofthe generatorsetwill

essarystepsforthe disassemblyofthe

disassemblyforgeneraloverhaulof

ngineandits accessories,themain

dthecontrolunit- willbegivenin

ecomesnecessarytorepairany

uetoanaccident,allthe stepsof

dinthesubsequentchaptersmaynot

vicingsorrepairsthatmaybecome

cludedin ChapterVIII.

beforethegeneraloverhaul,

rwhichthe maintenancepersonnel

y128,256,384,and 1,000hoursof

every25Ghoursofoperation,the

moved,inspected,cleaned,andchecked;

sofoperation,the valvesshouldbe

rator,andvoltageregulatorshouldbe

isualinspectionmadeoftheengineand

eneratorandexciter,andthecontrol

eseservicingsaregivenin paragraphs

3and 94.

ldtakeplaceafterevery2,048

gine,thealternatorandexcitershould

elyandanywornpartsreplacedorre-

hits controls,instruments,and

ycheckedandinspectedandanynec-

mentsmade.

YOFTHEGENERATORSET

eoil.SeeFigure102.

eeFigure102.

at theprimaryfuelfilter,

onnectallleadsandconnectionsfrom

it, disconnectingthemattheengine,

thealternatorandexciter,dis-

ernatorandexciter.SeeFigure102.

oltsfromthebaseassemblyof the

econtrolunitand baseassembly.

mountingboltsofthemaingenera-

hookedintheliftingeye ofthe

orenoughtoblockup theengineso

ntheblockwhenthemain generator

ON


/ h t t p : / / w w w . h




LBS

gineon GeneratorSet.

TG-317,30K.V.GeneratorSet,showlr-

pling,Fan,LiftingHook,etc.


/ h t t p : / / w w w . h




hatthe weightisevenlydis-

ksandthechainhoist.

pscrewfromthecouplingandthe

oldthe flywheelhousingand

dpullthe maingeneratorawayfromthe

tmountingboltsandwith the

romthe frame.

thecompleteoverhaul.

stallingGeneratortoEngine.

ON


/ h t t p : / / w w w . h




OFENGINE

DINSPECTIONOFTHEENGINE

emechanicshouldobservethecondi-

andassemblies,andheshouldalso

surementswhicharegiveninthefollowing

seobservationsandcheckswillindicate

mentsarenecessary.Ifthisdisassembly

eresultsonly inathoroughcleaning

essories,muchwillhavebeengainedin

lifeoftheengine andalsoassuring

e

s- rubberstopsandfelts-

.

e

cket

ersandSolenoidValve.


/ h t t p : / / w w w . h




OFENGINE

SSEMBLY

ndthebatterycharginggenera-

vebeenremoved,thefollowingsteps

ollowed:SeeFigure102.

dplug theholessonodirt can

movethemountingbracketto

maryfuelfilter,andthe solenoid

05.Removethefuelfilterand sole-

fuelfilter.SeeFigure105.

k-offlines,bothatthe injector

ump,asshowninFigures106and 107.

ctorLeak-offLineatInjector.


/ h t t p : / / w w w . h





OFENGINE

eclampsandunscrewthenuts at

hefuelinjectionpump.SeeFigure109.

attheinjector.SeeFigure 108.


/ h t t p : / / w w w . h





OFENGINE

lubricatingoillineto thecylin-

tionislocatedin thecrankcase

ectionpump.SeeFigure110.

LinetoRockerArm.


/ h t t p : / / w w w . h





OFENGINE

uelinjectionpump,andtheadapt-

gearhousing.SeeFigure 111.NOTE:

ovetheexternalrockerarmoilline

theyarecarbonizedandwill not

bepriedout asshowninFigure112.

exhaustmanifold.SeeFigure113.


/ h t t p : / / w w w . h





OFENGINE

nifold.

erandunscrewandremovetheeight

rarmassemblyin place,andremove

114.

ckerArmAssembly.


/ h t t p : / / w w w . h





OFENGINE

ectionstothepumpandremovethe

folds.Notethewaterdistributors at

rankcase.SeeFigure115.

ead.SeeFigure116.

terInletManifold.

nderHead.


/ h t t p : / / w w w . h





OFENGINE

ercover.Removebracketcap-

velifterbracketandthelifters, as

he fingersheldagainstthelifters

eirfallingthrough intotheoilpan

mp.SeeFigure118.


/ h t t p : / / w w w . h





OFENGINE

ftjaw,asshowninFigure118,and

ethecrankshaftdrivepulley.

casecover.SeeFigure119.

ntGearCaseCover.

thecam,idler,andcrankshaft,

r,asshowninFigure120.If the


/ h t t p : / / w w w . h





OFENGINE

hereit mesheswiththeothergears,

etheidler gearwithanoversizegear.

ndplay byinsertingafeeler

ubandthe thrustwasher.Thisclearance

7".See Figure121.Excessiveend

mebyreplacingthethrustwasher.

NOTE:Theidlergear capscrew

eFigure122.

,,;

rGear.


/ h t t p : / / w w w . h





OFENGINE

shaftlockscrewbyfirst re-

wninFigure 123.Theshaftcanbepulled

pe,asshownin Figure124,withthe

sher.

ushingclearancewithafeelergauge

ushings,whichshouldbebetween.002"

5.Ifthis isexcessive,thebushings

ructionsforbushingreplacementare

mshaftBushing.


/ h t t p : / / w w w . h





OFENGINE

thatholds thethreecamshaft

eFigure126),removethecapscrews,

AMSHAFTGEAR

ThrustPlateCapscrewLock.

f thecrankcase.Becarefulwhen

otto damagethebushings.

he

as

-

ted

e

-

e-

-

e

e

empt

ace.

ews

t

eeloffthebolts.Screwtheseintothe

huboftheflywheelandpushthe fly-

e 128.Thesecapscrewscanbeused

eeloutofthehousing.NOTE:In


/ h t t p : / / w w w . h





OFENGINE

hreadsontheflywheelboltsin the

ckon.

theengineonits leftside

ousingwiththeaid ofthechainhoist

ourcapscrewsanddowelboltnuts,as


/ h t t p : / / w w w . h





OFENGINE

eoil

e

s.

ch-r-

end

nd

n

e

nd

-

main

a

ween

he

s

re

wn

l.

e-

g


/ h t t p : / / w w w . h





OFENGINE

housing.Fourcapscrews,two

twodowelboltnuts,asshowninFigure

ecotterpinsfromthe connecting

dpushtherods outthroughthecylinder

ulnottomarthecrankshaftorthe

NOTE:Agoodpilottoolforpushing

oodenhandlewithapieceof copper


/ h t t p : / / w w w . h





OFENGINE

e tubeslipsoveronebolt andthe

idetoavoiddamagingthe bearing

Replacethecapsandthenuts ontheir

andtheconnectingrodsareall num-

UTION:Donotreversethe position

bereplacedintheiroriginalposi-

ectingRodBoltOver

e

e

he

oil

ELLOCATINGHOLES


/ h t t p : / / w w w . h





OFENGINE

ved,asshowninFigure136, withtwo

od,andtwobolts. NOTE:Themain

dconsecutively,startingatthefront

ine,1to7 inclusive.

werHalfOilSeal

shaftoutofthe crankcase,as

nottodamagethebearingsurfaces.

ps

nkshaft.


/ h t t p : / / w w w . h





OFENGINE

ofthe bearingoilsealanddis-

SeeFigure138.

romboththecrankcaseandthe

gsarenotnumbered.Therefore,they

emovedsothattheycanbe placed

cesexactlyastheycameoutif they

d.Eventheirindividualpositions

capsmustnotbereversed.If any

edorburned,itis recommendedthat

ot Justone.

e plugatthefront endof

therearend.SeeFigure139.

ereliefvalveand theoilline

gure140.

elydisassembledexceptforthe

heheadassembly.Inspectionandcondi-

ypartsof theaccessoriesaregiven

V.


/ h t t p : / / w w w . h





ofENGINEPARTS

CEMENTOFENGINEPARTS

e inspectionandrepairofthe

sheregiventakeintoconsideration

placementthatcanbemade.It should

,thatallofthese repairsorreplace-

mostpart, someofthereplacements

xtremeconditionsaregiveninorder

g askillfuljob.

tioncanbemadeonlyiftheparts

dout.If nocleaningtankisavail-

eroseneis recommended.

he enginepropertobeserviced

erhaulofthe engineaccessories

arthsteel,case hardened,andruns

chare pressedintothecrankcase.The

clearanceisfrom.002"to.0035".The

dened,willneverhavetobereplaced

ance.Thebushingswillneedreplacement

ve.Theinstructionsforthereplace-

kcaseinstructionsinparagraph10.The

canbecheckedbetweenthehubofthe

s showninFigure127,shouldbebe-

earanceisgreaterthan.015",the

ced.

he

unch.

ed

o

he

r-

g

d

k-

d,

42,


/ h t t p : / / w w w . h





removeany sediment,sludge,orre-

swithair.

hannel.

ROUNDANDTAPER

vewithaninsidemicrometeratthe

el,asshowninFigure143.


/ h t t p : / / w w w . h





DSLEEVES

allel tothecrankshaft,and

nglestothe crankshaft,asshown

cebetweenthesetworeadingsshows

eeveisout ofround.Toobtainthe

eevetaper,measureinlikemannerthe

ytakingtworeadings,oneposition

ndtheother atrightanglesto the

topparallelreadingwiththebottom

pright anglereadingwiththebottom

nthe taper.Iftheoutof round

n.005",thecylindersleevesshouldbe

shouldbereplaced.

DERSLEEVES

thedry typeandcanbe

ype

g-

ean

e

de

se-

r-

ths

er

ting

C",

a

found

ve

eengineserial numberwhich

plate.

NGCAMSHAFTBUSHINGS

ronzebushingswhichare pressed

siredcamshaftbearingclearanceshould

35".(SeeFigure125.)If theclearance

thebushings.The bushingsareof

equire reamingafterbeingpressed

BUSHING

efullycutthroughthebushing,

thecrankcase.Withacoldchiseland

gandknockitout.


/ h t t p : / / w w w . h





e

ace,

e

g

t

s

the

n

n

care-

d

aftBushing.

mainbearingsurfaces,onebetween

teachendof thecrankshaft.Thecrank-

callyanddynamically.


/ h t t p : / / w w w . h





GS

AFTWEAR

mberofmicrometerreadingsnec-

doutofroundof allthebearing

asoutlinedinthe followinginstruc-

hesereadingsberecordedinsome

gure 147.

rdingMicrometerReadings.

aringsurface,orjournal,with

eter.SeeFigure147.Beforerecording,

ejournalto findthelowestreading

mallestdiameterofthe bearingsur-

atone end.Usingthatsmallendas

readingsin line,oneatthesmall

dleof thebearingsurface,andthe

cordthesereadings.Thesethree

untoftaper inthisline ofthisjour-

quarterofthewayaroundthis bear-

eereadingsinline, thefirstat

middle,thethirdatthe otherend.

werehorizontal,thesecondthree

orviceversa.The secondthreeread-

er inthatplane,or thevertical

foutof round,comparethefirst

efirstverticalreading,the second

esecondverticalreading,thethird

ethirdverticalreading.Repeatthis

bearingsurfaces,bothmain andcon-


/ h t t p : / / w w w . h





025"to.004"whichis takenoffthe

nalsizeofthe shaftis2.996"to

shaftismorethan.0015"or measures

kshaftshouldberegroundto astan-

,.030,or.040ofan inch,depending

gsare2-1/8"andthebearing

whichisalso takenofftheshaft.

eofthecrankpinis 2.121"to2.123".

nismorethan.0015"or measuresless

e-groundto oneoftheundersizes

gefornicksandsmooththemif

oltsshouldbetightinthe flange.

r burrsthatmightcutthe oilre-

e oilslingeris bent,straighten

mageit.

s

nkshaftWear.

FTGEAR

rforwear.Ifwornexcessively,

amesize asmarkedontheoldgear.


/ h t t p : / / w w w . h





EARINGS

NDCONNECTINGRODBEARINGS

ledrilledfor pressurelubri-

e sideclearanceoftheconnecting

bearingandthecrankshaftshouldbe

8",maximum.012".SeeFigure132.

LACINGCONNECTINGRODBEARINGS

k,precisionbearingswhichrequire

eplaceable.Ifnecessary,thesebear-

ng

g-

is

er-

e-

dard

-

s

ce)

ad-

the

ed

at

ce

ft

LACINGTHECONNECTINGROD

econnectingrod,usuallythe

d,as eventhenewbushingwouldfit

nAligner,HeadDown.


/ h t t p : / / w w w . h





MENTOFCONNECTINGROD

grodassemblyclampeduntothe

ure,swingtherod intoahorizontal

or).See Figure150.Withthe

erod (Pistonheadpointingtothe

etweenthefaceofthe fixtureandthe

ninFigure150;ifthis spaceis

wistedoutofline.NOTE:Thering

onaresmaller thantheskirt;there-

oftherodalongthe fulllengthofthe

h alargewrenchuntilspacebetween

iseven.SeeFigure151.Nowcheck

toAlignment.

directionbymovingthepistoninto

othe rod(pistonheadpointingup).

hespacebetweenthealignerfaceand

InAligner,HeadUp.


/ h t t p : / / w w w . h





uneven,twisttherodwithalarge

ntisobtained.Checkfora bentrod

parallelpositionwiththeconnecting

servethe spacebetweenthealigner

nAligner,PistonParallel.

thespaceisnoteventhe rodis

ghtenbycarefullybendingtherod

RodinAligner.


/ h t t p : / / w w w . h





derheadandallits parts,re-

s.Checktheheadforcracks.Check

rtubesandclean.Thesetubespartially

besareshowninFigure184.

ACINGAIRCELL

dinplacebystuds andnuts.

ange hasbeenremovedbytaking

eaircellplug canberemovedfirstby

ameterwitha washer,andpriedout

e innercellcanthenbe removedby

e156.

jectormaybefaulty,andthere-

carefullycheckedasgivenin para-

heaircellforburned spots,paying

eadingedgeof theaircellwhich

ctorwhentheair cellisin place

outany carbondepositswithapiece

emerypaperoranymetalin removing

notchangethecontouroftheair cell

ternally,replacethe aircell.

ES

withacompressorandremovethe

Figure157. Releasethecompressor

springand valvespringseatandvalve

Thevalvecannowbe removed.

ecktheedgesaroundthegroove

ts tobecertainthatno burrshave

gorremovingtheclip.The burr,or

ON


/ h t t p : / / w w w . h





dewhenthevalveis slippedout;there-

ha handstonebeforeremovingthevalve

m.

ANDVALVEGUIDES

takevalveseatsforcracksor

eatscanbereplacedif theyarein

ntakevalveseatscanbe refinished

grinder.Checkthevalveguidesfor

nd notingtheamountofsideplay.If

etheguideandalsoreplacethe valve.

AUSTVALVEINSERTS

-

rt

e

y

rt*


/ h t t p : / / w w w . h





uldexercisecaresoasnottomar

d.

esaroundthehole andbesure,

o installthenewinsert,chillit

placewitha drivingtoolasshown

essarytorefinishthevalve seat

inder canbeusedonthe intakevalve

ableorclimaticconditions

proceduresarenot feasible,the

d:

nderheadstandinthesun until

nheat it.Coolthevalveseatin-

hen drivetheinsertintothe block

veinsert oniceorlet itre-

horoughlychilled.Removethechill

llingthe waterjacketswithboiling

ytochangethewater threeorfour

headsufficiently.Withthewater

oretainasmuchheatas possible,

n placeasshowninFigure160.

VES

erplace.Makecertainthatthe

xhaustports andthattheintakevalves

tallthesafetyclipin thegroove


/ h t t p : / / w w w . h





nin Figure158.Assemblethevalve

t.Compressthespring asshownin

etainer halves.NOTE:Keepeach

ngobackin itsoriginalplace.

TRIBUTORTUBE

tortubefromthecylinderhead

eanyrustandfree anyholesinthe

Ifthe tubecomesloosefromthepipe

acethetube. SeeFigure187.

ANDROCKERARMASSEMBLYANDPUSHRODS

esandrockerarmassemblyincludes

seats,retainers,lifters,rocker

crews,andthebrackets.Theinlet

s1-3/8";theexhaust,1-3/16".

VESFORGRINDINGANDREPLACEMENT

burned,theymustbereplaced.

ouldberefacedinarefacingmachine

ESPRINGSFORREPLACING

feachspringwith aspringscale

Thetensionsshouldall beequal.If

ked,orbroken,replacethespring.

ompressedtothe lengthof2"

nposition,the scaleshouldread

esired;whenthespringis compressed

hereadingshouldbe84- 89Ibs.,

SANDBRACKETSFORREPLACEMENT

typeandismadeofgrey ironwith

eadforcracksandreplaceif cracked.

bracketbyinsertingalifterin

reloose ormorethan.0015,

ters.

INERSANDSEATS

identshouldit becomenecessary

seatsand retainers.

fterevery1,000hoursof oper-

atersolublevalvegrinding compound.

esitscuttingpropertieson contact

ol liketheoneshownin Figure

mmended.

47


/ h t t p : / / w w w . h





RING

CEDURE

pressthespringsand removethe

nFigure157.Clean thecarbonoff

orts. Donotcleantheoil varnish

epitted, theyshouldberefaced

smallquantityofvalvegrinding

ustsufficienttocovertheseating

a lightbutfirmpressureletting

t thevalvefromtheseatevery

egrindingtool crank.ASsoonastne

,washthevalveandseatin kerosene

valve.If thevalvefaceorseathas

em,thisindicatesthateitherthe

wasgroundout,ortoomuchpressurewas

ot liftedofftheseatsoftenenough

on.Therefore,thegrindingmustbe

theappearanceofgreyemery

ntofPrussianBlue onthevalveface.

afaint traceofblueappears.Insert

veontheseatonecompleterevolution

e valveseathasaslight ringcom-

swill indicatethatthevalveis

s notcomplete,thevalveand

etecontactandmustbeground until


/ h t t p : / / w w w . h





G

mpoundwhenthejobisfinished,

tall loosepiecesofcarbonaroundthe

tweenthepistonheadandcylinderwalls

ll-donejobsofvalvegrindingare ruined

particlesof carbon.

HEELHOUSING

earfordamagedteeth.If teeth

hanewringgear. Examinethebolt

worn,replacetheflywheelandfly-

llhousingfor cracks;ifcracked,

ngboreshouldbecheckedforout

mentwhenreassemblingengine.With

the flywheelasshowninFigure

netocheckthebore.The maximum

fmorereplacethehousing.

R

ar,laytheflywheelflatonthe

theflywheelup.Witha 3/16"drill,

oughthegearparallelwiththe teeth

hecenteroftheflywheelto therim.

remainingmetalbetweentheholesto

two.Drive offtheringgearwith

thenewring gearinoilfor fifteen

thatorch toexpandthegear.With

r,front sideorcrankshaftsideup,

placewiththebevelend oftheteeth

sseatedproperlyagainsttheshoul-

49


/ h t t p : / / w w w . h





sthecamshaftandthefuelpump

interposedbetweenthethree.See

andaccessorydriveshaftturnin the

kshaft.Thegearsareon fixedcenters,

ebyselectingoversizeorundersizegears.

studwhichispressed intothe

uredbyalockscrewwhichscrewsinto

ase.SeeFigure123.Thetiming

andsteel,aselectedcombination

wear andquietrunning.

ANDREPLACEMENT

camshaftgearsshouldbefitted

thefuelpumpdrivegear canhave.005"

ndparagraph4,step16. Whenordering

usethesizemarkingof theoldgear

theothers.

numberwithineitheran0or a

rroundingsymboldenotesoversize

tively,andthe numbergivesthedevia-

housandthsofaninch.TheletterS

TE:Thenewgear,orgears,for re-

ndinsizetothegear orgearsreplaced.

madeforwearonthe othergears.


/ h t t p : / / w w w . h





kshaftGear.

crankshaftgear,pullit off

wninFigure164.Toinstall anew

ep9 andFigure177.

RGEARBUSHINGS

hebushingneedstobereplaced.

placed,itmustbeboredin alathe

.Handreamingwill notbestraight,

runout.Theclearancebetweenthe

shouldbe.002"to.0035"ofan inch,

mmendedanewidlergearbe installed

r.

P

NGJOURNAL

inBearing.


/ h t t p : / / w w w . h





dcopperlead ofsteelbackedpre-

acedindividually.Noscrapingand

mentcaneasilybemadeinthe field

ld shellasshowninFigure 165.This

ntotheoilhole inthecrankshaft

cticallythesamediameterasthe

htheheadfiled downtolessthan

kshaftbyhandandpush theoldshell

sshowninFigure166,start the

beingcarefulnottomarthe bearing.

sertthesamebolt thatwasused

e,allowtheheadtoprojectoverthe

mraisingupas youslowlyturnthe

almostinplace,stopandbackup the

oltfromover.the shellandinsert

erbutwithahigher head,andslowly

nbyturningthecrank.

W

TOILHOLE

NGJOURNAL

BearingShell.

thatifonemain bearing'needsre-

eplaced.TheuppersheLlsare not

beingdowelledinthe capstohold

e required.

S

he bearingsurfacesandcheck

thaninsidemicrometer.Itis necessary

nthecaseandthe capsclampedon,

asurements.Ifthereare"pin"holesand

the crankshaftwearislessthan

bearingsofstandardsize.-Newmain


/ h t t p : / / w w w . h





000".If themainbearingwearis

rankshaftwearisnegligible,replace

standardsize.

ainbearingcapoilstops.If the

available,thegroovescanbepacked

ouldbefirmlycalkedintoplaceby

ol orpunchandhammer,poundingthe

roovesuntiltheyarepackedfull.

n oildraintubeattachedtoit

eoillevelin theoilpanin orderto

sthrough therearmainbearing.

witha tubeinplace.Replacetherear

placetherearbearingoilseal

mthe gr,oovewithaknife,butdo

etal.Coatonesideofthefelt with


/ h t t p : / / w w w . h





o thegroovewiththeshellacside

68.The shellacmustnotbeallowed

ecrankshaftsideof thefelt.Oil

graphitegreasetokeepthemfron

eis firststarted.

ers13087through13096,13170

through13216areprovidedwith bronze

ecrankshaftendplay.The thrust

,upperand lower,andareinter-

whichholdthethrustflangesinplace

randreplacedifnecessary.

malloyand havefourringsabove

n. Thetopthreeringsare compression

reventilatedoilrings.If the

ced,thiswillnecessitatereplacing

nsand connectingrodshavebeen

onringsremoved,thoroughlycleanthe

thegroovesandring landsforcracks,

inglandsforbums.Replaceifthey

ochecktheheadofthe pistonandthe

orcracksandreplaceifnecessary.

rance(atskirtbottom,90° to

new.

RANDREPLACINGTHEPIN

lfloatingtypeandaremadeto

ortheconnectingrodbushings.The

eansoftwosnaprings whichlockin

ofthepistonpinbosses whichprevent

in contactwiththecylinderwalls.

oovesarenot wornsothatthelocks

pistongrooves.Thepinshave the

edto preventtheircuttingthrough

pistonisa.001"to .003"tightfit.

ingrodbushingis.0014to.0009If

,replacethepinwiththenextfirst

piston andconnectingrodbushings.

connectingrodandream ittofit a

dedthatthere isnowearbetween

earbetweenpistonandpin,a

tbeused andthepistonandconnecting

It willbenecessarytorealignthe

graph18.

ON


/ h t t p : / / w w w . h





es,

s

s

he

y

ACING

r

d.

100hoursofoperation,apiston

removedfromtheengine,alwaysreplace

is isadvisablebecauseitwillbe

nrings backintothesamepositions

e,iftheyare notreplaced,there

nspumpingoil.It isalsorecom-

wringsontothepistonsuntil they

ntotheengine.Checkthedepthof

thegrooveclearanceasshownin Figure

ontrolringto grooveclearanceis

g, whichisthetopring, togroove

heckthegapsof alltheringswith

Figure171.Thecompressionringgap

d theoilringgap,.010"to .015".


/ h t t p : / / w w w . h





EMBLY

SSEMBLY

psofreassemblyoftheengine,

nmindthat dirtistheengine's worst

rtsshouldbewipedclean,andnote

Donotuse wasteforwiping;use

e canbeusedtoblowoff anyfine

epartsafterwiping.Onlyclean

oilingtheparts astheyarere-

aceallgaskets,oilseals, felts

newones.

recommendedsequenceofre-

kcaseissetonits studsandsupported

heoilline plugs.Insertone

eryoilline (seeFigure141),three

kcase,oneatthebottomside,and

ecrankcase.SeeFigure139.

t andrearendsmustbe screwed

ankcasesoasnot tointerferewith

elhousingandthe timinggearhousing.

s inthefrontendand "Perma-

ear housingandgasket,andtighten

ocounter-sunkcapscrews.SeeFigure172.

sare new,eachmustgobackin

fromwhichit wastaken.Theirposi-

notbereversed.Inserttheupper

sin thesupport.SeeFigure173.

therearbearingoil seal

nsertenoughgasketstolocatethe

fwaybetweenthecrankshaftoil

ON


/ h t t p : / / w w w . h





EMBLY

ltheads,so theclearancebetweenthe

goilsealis .004".SeeFigure174.

ew oilsealfeltis inplace.

spositionhowever,cannotbe

aftislaidin place.Ifthissettingis

kshaftandadd orremoveoneormore

essary:Thesamenumberandthicknesses

boththelowerandupperhalvesof the


/ h t t p : / / w w w . h





EMBLY

haftinplaceso asnottomar

lywheelboltsshouldbein placebe-

aft.Notetheextraholein thecrank-

thepurposeofgettingatthe fil-

pperhalfoftherear bearingoilseal

sealwithouthavingtotake outthe

5.

ofthe oilretainersealontothe

re175.Besure toputthecoppergas-

rhead screw.Beforeinstallingthe

e lowerhalfoftheoil sealassembled

positionofthe upperhalfoftheoil

kshaftasinstructedinStep4. Ifnot

ed.NOTE:Newoilstopsshould be

oil stopssealthesidesof thecap

entoilfromleakingthrough.

p,be carefulnottoteartheoil

pin place.Afterthecapisdownin

oilstopsflush.

re numberedfrom1to7,starting

ngon frontend.Withthebearing

shouldbe installedintheirrespec-

glecastlobeisfacingthe camshaft

WrenchonMainBearing.


/ h t t p : / / w w w . h





EMBLY

re 137.Tightenthemainbearing

renchtoatensionof 125to135foot

heboltthreadsshould bedryand

tbyhandtobe sureitis free.Before

eckthecrankshaftendplay.Slipa

endsofthe rearmainbearingandthe

ure131,andrun thefeelergaugeclear

erclearanceis.003to .009.Ifmore

ar mainbearingorthrustflanges.

removedfor replacement,press

ecamshaft.Makecertaintoalignthe

onthewireretainingring.Oil the

tallthecamshaftintothecrankcase.

endplay,measurethespacebetweenthe

rustcollarwiththeshaft pulledfor-

27.This measurementshouldbe.003"

,this canbecorrectedbyreplacing

arorthecamshaft.Usuallyreplacing

omeexcessiveendplay.Installthe

ightenthecapscrewsandbendthecap-

the capscrewhead.

tructionsaregiveninthe event

adtobe removedandreplacedbyanew

allingthecrankshaftgearis to

ely15minutesinorder toexpand

ble.Attheendofthis time,pickup

rsandslipit ontothecrankshaft.

atandthekey.This methodofheating

mexpansionwithnoinjuryto thegear.


/ h t t p : / / w w w . h





EMBLY

snot feasible,pressonthe

77.Forthisprocedure,along7/8"

sameoutside diameterasthegearhub,

dagainsttheendof thepipe,anda

studareneeded.

withwhitelead.Placethegear

withthekeywayandthe keyinalign-

heshaft. Placethepipeoverthe

ceand tightenthenuttopress on

be certainthatitstaysin position.

aft.SeeFigure178.Besure

leinthe shaftwiththesetscrew

NOTMISTAKETHEOILPASSAGEHOLEFOR

eFigure123.Insertandtighten the

pergasketonthesetscrewandinstall

nut.Install theidlergearonthe

umbersoutsothatthe oilslinger

dsthecrankcase.

etwo marksontheidlergear

one withthemarkonthecrankshaft

theidlergearwiththe markonthe

Figure163.

placedandthe markswerenot

rs,thetiming ofthevalvescannot

e installed.Theprocedurefortiming

29.Installthei dlergearretaining

thescrew.Thisscrewhas aleft

thatthewasheris startedonthedowel

eidlergearend play,whichshould

N


/ h t t p : / / w w w . h





EMBLY

feelergaugebetweentheidlergear

eras showninFigure121.If theend

herreplacethe retainingwasheror

esuretousenew coppergaskets

e surethattheyareproperlyin place.

veandtightenthe fouroilpump

5.(Nowlaytheengineonits rightside.)

onnectingrodassemblyin avise

amagingtheconnectingrod,sothat

instthe topsideofthe jaws.With

h,cleanout eachringgroove.If

eringlandsandthe ringhasnotbeen

nstructionsinparagraph42,thechecks

tallingtherings. Installtherings

thegapsofthe rings90° apart(a

wnin Figure179.Thethreetoprings

efourthandthe fifthringsatthe

.

dconnectingrodsintotheir

rrowonthetopofthe pistonshould

fthecrankcase.Placearingcom-

howninFigure180.Makecertainthat

irgroovesbeforetighteningthecom-

e,pausingto pushthecompressor

heringsare free.Compressasmuch

woodenguide,showninFigure134,

pperconnectingrodbolt toguidethe

ringthebearing surfacesofthecrank-

.

61


/ h t t p : / / w w w . h





EMBLY

nectingrodassemblyshouldbe

er,makingcertainthatNo. 1piston

edesignatingnumberontheside of

cingtherightside oftheengine

andsoon foreachrespectivepiston

hepiston intothecylinder.Ifit

ertherings arenotcompressedenough

chingon thecrankshaft.

apandmakesure thatthenumber

dlinesup withthenumberoftherod.

geableorreversible.Tighteneachcap

rench.Thetorquetensionin foot

n75and85. Checkthesideplayofthe

geachcaplightlyasshownin Figure

e from.003to.008,maximum.012",

hafeelergauge.NOTE:Ifthere isno

nnectingrodmust beremovedand

aponthecrankshaftjournalto

eways.Ifnot,the capandrodmust

ononeside.Usuallya fewstrokes

eclearance.Ifthereis sideplay,

ee whentappingthecapandrod,there

gorthebearing isnottheproper

earingclearanceshouldbebetween

m.0055".

es,between75and85footpounds

ertpinsof largeenoughdiameterto

e.Thecotterpinshouldextendabout

hlength forbending.Iflonger,cut


/ h t t p : / / w w w . h





EMBLY

nnectingRodforSidePlay.

andbracketassembliesin

dtightenthecapscrews.CAUTION:The

ldingtheassembliesinplaceopen

ore,andif, foranyreason,anyof

ced,ONESOFIDENTICALLENGTHMUSTBE

etheywillbendinthe cylindersleeves.

bercoverwiththe gasketinplace

covernuts.

gcapdraintubeandalsothe

screeninplace.SeeFigure130.

oil panandrecheckalltheconnect-

inbearinglockwiresbeforeinstalling

an.

singbyslipping itintoplace

he twodowelboltnutsandfour cap-

ure129.

theengineuprightsothat it

ngandblocksof woodplacedonthe

ankcase.

reliefvalvemakingsurethat

ring areclean.SeeFigure140.

ountingbracketonthe gear

63


/ h t t p : / / w w w . h




EMBLY

-

er

e

n

eeves

ht-

uts

nds

76.

der

ets

d.

ing

s-

e

nd

n

eld

and

old

em

nto

e

d

noservicingorreplacement,

alledas aunitafterthepush rods

asnecessarytoreplaceorservice

push rodsasbefore,andsetthe

ce,juststartingthe bolts,making


/ h t t p : / / w w w . h




EMBLY

racketsgointheir properplaces.

ein theirrespectivepositionsand

turning itasit isbeingpushed.

HOLES

kerArmShaft.

eentheoilholes intherocker

edwiththe threadedholeinthefirst

rmshaftisin position,screwin

tud.A goodmethodforinstalling

ockedagainsteachother andwith

Figure 185,tightenthestudin place.

cketstudandinstall thespringclips.

Stud.


/ h t t p : / / w w w . h




EMBLY

RMSHAFT)

BOW

kerArmShaftOilLine.

haft oilline.SeeFigure186.

butorinthecylinderheadwas

fservicingthecylinderhead,install

187.

wheel,makecertainthatall

dfromthecrankshaftflangeandthe

ntheflywheel.Feelthesurfacesfor

derHeadWater


/ h t t p : / / w w w . h





EMBLY

Housing.

e188.To facilitateputtingonthe

enginewith thefuelpump,moveNo.1

d-center.Nextlineupthetimingmark

rontop-dead-center)ontheflywheel

eflywheelhousing.SeeFigure188.

heflywheelgoeson inoneposition

ers

e

d

ev-

-

89.

tor

bore

ee Figure189.Checking

out.


/ h t t p : / / w w w . h





EMBLY

vebeenreplacedand thepunch

ming werenottransferred,thefol-

gthevalvesisnecessary.

valverockerarmofNo.1cyl-

romthetiminggear,see Figure185)

eof.010"andtheidlergearis notin

hingwith theothergears.NOTE:The

eis.009".The readjustmentmustbe

he

.

ter

e

ure

nk-

-

s

ft-

y

?Figure190.Flywheel

shTimingHolein GearHub.

aftgears.Installthecamshaftthrust

ustscrew.

ming,slowlyturnthe crankshaft

hedirectionofits rotation.Toward

ndrevolution,rotatetheNo.1cylin-

slightdragisfelt,the timingmark

ywheelshouldbeinthe centerof

ywheelhousing.

efuelpump andgovernoras

ionpumpwiththeengineasfollows:

thedirectionorrotationso thatNo.1

gure185.Slowlycontinueturning

ingmarkNo.1 F.P.I,ontheflywheel

See Figure190.

uel injectionpumpsothat

e,shownin Figure191,isin thecenter

earhub.SeeFigure192.


/ h t t p : / / w w w . h





EMBLY

T|mjngCfarHo

erOilSeal.

hree

on

hehub

p

ten

din-

he

2.


/ h t t p : / / w w w . h





EMBLY

andrivepulley,line upthe

driveit inasshowninFigure 196.

eloil filter.

ilter andsolenoid,orsafety

dingbracketandinstallthe bracket

ure105.

l filter.

he nozzleholderandnozzle

ngthenozzleholderassembly,the

shouldbe thoroughlycleaned.Always

:Theassemblyshouldbecarefully

tipdoesnotstrikeagainstthe re-

ecuringnutsshouldbetightenedevenly

hestuds.

urelinesand leak-offorfuel

tthev aresecurelytightened,and

eFigures10G,107, 108,and109.

ket

kshaftPulley.


/ h t t p : / / w w w . h





EMBLY

onsbetweenthefilters,the

ctionpump.SeeFigure197.

nectionandDirectionofFlow.

kerarmoil linefromcrankcase

and fanassembly.

and hoseclamps.

r inthestartermotorhole in

ghtenthethreecapscrews.

ndinstall thefanbeltand

Thereshouldbeapproximately3/4"

N


/ h t t p : / / w w w . h





EMBLY

asuredonthelongestside ofthe

makes.SeeFigure198.

elyassembled,andisready for

andthecontrol unit.

Y


/ h t t p : / / w w w . h





DINSPECTIONOFTHE

anlinessusedin overhaulingtheengine

noverhaulingthecomponentsystemsof

ainservicingsthatthe maintenance

.Thisappliesparticularlytothefuel

ntricateequipmentforthefinecalibra-

ry,togetherwithahigh degreeofskill

e,noattemptshouldbemadeatmajor

onpump.Thewholeunit shouldbe

designatedbaseor thefactoryshould

umpshouldbecarriedbythe maintenance

ncludedare:fuel,electrical,cool-

:Althoughtheaircleanerispart

,instructionsforservicingthe air

efuelsystembecauseits functionis

ystem.

epares,controls,andtimesthe

ne.Thefuelpassesfirst,through

e fueltransferpumpwhichmaintains

othe secondaryfilter,thenthrough

-offvalvetothe fuelinjectionpump,

tedthrough theinjectionlines,and

ntothe combustionchambers.The

theexcessfueldeliveredbythe

hthecheckvalveinthe fuelinjection

efueltank.Figure197illustrates

he.flowoffuel,a singlespeed

egulatesthespeedoftheengine.The

teofoperationatan evenpacefor

set.See Figure199.


/ h t t p : / / w w w . h





f theconstant-stroke,cam-

rtype.Itspurposeistometerthefuel

preciselyata definitemomentin

pressuretothespraynozzlesby which

ectivecylindersoftheengine.See

p,havingaself-containeddrive,

numalloyhousing(16,Figure200)

CTION

View.

entinthelowerhalfandsixpumpelement

half.Thecamshaftcompartmentcon-

ichrunsin ballbearings(12)supported

).Feltcushions(50)in theclosing

basefacilitatelubricationofthecams

appet assemblies(42).Directly

eplungerandbarrel assemblies(3),

othedsegments(5),plungerreturn

39 and41)andthecontrolrod (37).

singcontainsthefuelsump,de-

3)withgaskets(24),deliveryvalve

veholders(17)andnipple nuts(68)

argetubings.

nat halfenginespeed.Thecams

aftinthe sameorderasthefiring


/ h t t p : / / w w w . h





CEDATA

ervicebuiltintothefuelinjection

tuponthepreservationofits precision

areandmaintenance.

eto dismantleorrepairthefuel

ofthespecialtoolsandfinecalibra-

pthatis damagedorhasfailedshould

e,and theoldoneshouldbe returned

atedbythe OrdnanceDepartmentwhere

nt,anddatawillbe availablefora

oftheplungertype,andis mounted

npumpasshowninFigure 199.

veredby thetransferpumpis

nthe dischargelinewhichcontrols

theplunger.Theplungertappetis

ontactwithoneofthe camsonthe

byaspring.

fuelis suckedthroughaspring

erchamberandforcedoutthrough the

urnstroke.Thebackpressurein the

eplungerfromfollowingthecamduring

hof thestrokedependingonthe

ikelybecausedbydirtor a

heproperfunctioningofthevalvesor

veretainerwillpermitanexamination

andspring areaccessiblebyremoving

w.

efuel transferpumpbereplaced

psandthetransferpumpreturnedto

edbytheOrdnanceDepartment.

e transferpumpisequippedwith

gthe system.Iftroubledevelopsin

easaunit.

TIONOFFUELINJECTIONPUMP

on(seeFigure201)thefuel enters

tofthehousing.As soonastheupper

its downwardstroke,opensthe.two

rtsinthebarrel,knownasinlet and

esinto thebarrelwhiletheplunger

ke(see"A",Figure201).During the

ON


/ h t t p : / / w w w . h





IVERYSTROKEENDOFDELIVERY

ectionofBarrelwithVarious

ons.

okeoftheplunger,someofthe fuel

kintothesump,throughtheinlet and

woportsare completelyclosed.With

ng-loadeddeliveryvalveislifted

deliveredthroughthedischarge

e,whenceit isdischargedintothe

eengine(see"B",Figure201).

port

ber

mp by

and

ng

not

s

",

on

el

er

s

5b),

with

at

o

s

eFigure202.Sectional

Viewof FuelInjection

pumpElement.


/ h t t p : / / w w w . h





DELIVERY

iousPlungerPositions.

ecorrespondingteethonthe control

the latter,eithermanuallyorauto-

vernor,theplungeris rotatedinits

movedawayfromits"stop"posi-

eristherebyturnedin itsbarrel,

the by-passportandthesmallerthe

be (seeFigure203).Thefarther

wayfromits "stop"positionandthe

d initsbarrel,the laterthehelix

the largerthefueldeliveryperstroke

y,theplunger,bymovingthecontrol

stop"position,is turnedfarthest

erylateopeningofthe by-passport

aximumeffectiveplungerlift.For

trolrodat the"stop"position,the

reluntilits verticalgrooveregis-

n thisposition,thepressurecham-

antcommunicationwiththesump

calstrokeoftheplunger;therefore,no

ter.

geruncoverstheby-passportin

partoftheupwardstroke,the

mmediatelyreleasedandthedelivery

oits seatbythecombinedactionof

ferenceinpressurewhichthenexists

edischargetubing.This closesoff

hepressurechamberinthe barrelandthe

rystroketakesplace.In returning


/ h t t p : / / w w w . h




lveperformsadoublefunction:

drainingoffuelfrom thedischarge

swellas duringthesuctionstrokeof

evesthepressurein thedischarge

is accomplishedbymeansofthe

displacementpiston.

ctuallyreseatsafterthehelix

edtheby-passport inthebarrel,it

edischargetubingby increasingthe

tyequalto thevolumeoftherelief

downintothedeliveryvalveseat

Asaresult ofthisrapidreduction

veat theotherendofthe discharge

hus instantaneouslyterminatingthe

ynozzleand therebyeliminating

fueldeliveryper strokeis

fthecontrolrod,oneendof whichis

roftheengine.Thereis acertain

ntofthecontrolrodin its"stop"position,

edabout3/16"fromitsfullstop posi-

commences.Fromthatpointon,how-

eliveredis directlyproportional

ntrolrod.

dpoweroutputare controlled

amountoffuelinjectedintothe

clearlyexplainedintheprecedingchap-

mountoffueldeliveredbytheinjec-

sregulatedbythesimpleand foolproof

plungers.

NJECTIONPUMP

tionpumphousing(camshaftcom-

befilledwitha goodgradeofengine

evelof whichcanbedeterminedby

(Figure199).Thisoilgaugerod is

dicatingthe highestpermissiblelevel

velisrepresentedby theendofthe

oil showsuponitswithdrawalfrom

elis toolowandmustbe broughtup

nreached.Theoilisfilled intothe

injectionpumpoilfiller andbreather

helubricatingoilinthe pump

ineoilischanged.Tofacilitatethis,

ousingisprovided.

equire anylubrication,since

dinthe fueloil.

estopseeparagraph66.

7


/ h t t p : / / w w w . h




ozzleandfiozzleHolder).

OLDERS

rorthe nozzleandnozzleholder

uantityoffuelreceivedfromthein-

necombustionchamberinadefinite

mannerastoproducethemosteffi-

e.Thespraynozzlesareoftheclosed

pring-loadedvalvewitha seatat

closetheorificeaftereachinjec-

ginecombustionchamber.Thevalve

ythepressureofthe fueloilbeing

ump.SeeFigure204.

e

e

e

ed

s

tof

by

ulic

dy

anged

-

n

o-


/ h t t p : / / w w w . h




h

-

ped

e

n-

es

onat

r-

oil

ryspringandmeansofpressureadjust-

ionofthe nozzlevalve.SeeFigure

evalvehasanextensionofre-

oasthestem,whichmakescontactwith

g-loadedspindle.Adjustmentofnozzle

ccomplishedbymeansofthespring

TIONOFNOZZLEANDNOZZLEHOLDER

elfromthe injectionpumpenters

t connectionandpassesthroughthe

essurechamberjustabovethenozzle

essureof fuelactingonthediffer-

eedsthepre-determinedspringload,

seatand thefuelwillflowfrom

mthe pumpceases.Then,apositive

eloccursasthevalveis snappedto

ewhicheliminatesthepossibilityof

geoffuelbetweenthe lapped

evalveandits bodyisnecessaryfor

ilaccumulatesaroundthespindle

tmentfromwhichitdrainsthroughthe

idedforthatpurpose.


/ h t t p : / / w w w . h




TROUBLE

oworstfactorscontributingto

stingofminuteabrasiveparticles,

thefitof thestem,anderodesorclogs

esstickingofthe needleinitsguide.

rrosionwhichresults inenlarged

gneedlevalves.Itis important,

uelgetsintothe nozzle-fuelthat

.Thefiltersshouldbedrained of

tecleanlinessshouldbeobservedwhen

zlestogetherwiththe highpressure

dreassembled.

LEFROMTHEENGINE

es,applykeroseneorfueloil

orderthat dirtandgreasemaybe

etubingand leak-offlines,as

08 andcovertheiropenendswithcloth

ainstthe entranceofdirt.

sandpull theassemblyfromthe

ostrikethe endofthenozzleagainst

emblyis stuck,dueprobablytocar-

movedwithtwopry bars,asshownin

RAULIC

ure

ent

0

are

o

ster,

UNDS

or

age,

nd

WHEN

TOBSTRUCT

ESTHE

INTHE

WAY

S.Use

uld

ureFigure207.Operating

ster.


/ h t t p : / / w w w . h





E

eis generallyrequiredforthe

ericanBoschnozzle,itisrecommended

ot lessthan100strokesper minute

s lower,thethrottlingactionof

emtodribble andejectflags,making

onimproperly.Howeverifthethrott-

ordribbletowithin300 poundsofthe

e,thevalveseatcanbeconsidered

ajetappears,thevalveis not

hcleaningusuallycorrectsthetrouble.

vetobe replaced.

ZLETESTER

heendof thecouplingandoperate

flows.

lderassembly,asshownin Fig-

ya fewquickstrokestolever

ratesextraordinarilyhard,itindi-

tethespray patternandlookfor

ragraph56.Ifplugged orifthereis

beremoved,cleanedandlappedaccord-

nin paragraph60.Thevalveopening

7BudaDieselengineis 2,000pounds.

0pounds,thenozzlemustbe adjusted

aragraph:


/ h t t p : / / w w w . h





PENINGPRESSURE

zleprotectioncapexposingthe

essurecanbeincreasedordecreased

ring compressionscrewasshownin

ustmentsandtestuntil thecorrect

ed.

EATTOTHENOZZLE

he pintlevalvebodywithclean

shing withasoftwoodstick.Cloth

onthepintleandshould notbeused.

estem endonly.Usingfueloilfor

eatby rotatingthevalvebackand

patienceareoftenrequiredinre-

fromthe pintlevalve.NOTE:No

beusedinlapping thepintleinthe

weenthepintlevalveandthe bodyis

LEANINGOFTHENOZZLEANDNOZZLEHOLDER

arbonfromtheassemblywitha

assemblyin avisetoremovethe

ovethespray nozzle.

awn

-

y

ore

esN

on-

ces.

low

ft

dby

uck

kedin oilwillbehelpfulin removing

OOLS,EMERYCLOTH,CROCUSCLOTH,

RABRASIVESOFANYKINDSHOULDNOTBEUSED

ES.


/ h t t p : / / w w w . h





t

ebodycanbecleanedbyforming

oakedin oil,thepointofwhichwill

the nozzlevalveseat.Theorifice

edwithawoodsplinter.

ozzlebody maybecleanedwitha

bonsolvent.Do notattempttoscrape

roundtheorificeasserious damagemay

evalveand thenozzlebodyin

mbly.

NGANDREASSEMBLYOFNOZZLEHOLDER

sket.

ngtensionadjustingscrew.

atsofthespringretaining nut,

SeeFigure209.

in

e

le

t

f

d

le.

ace

ving

se.


/ h t t p : / / w w w . h





NOZZLETOHOLDER

ppedendof thenozzleholder

ngsurfaceofthenozzleto assurea

rfaces.

thenozzlecapnut beforere-

henozzlebe perfectlycen-

orthispurpose,an assemblingsleeve

ozzle.Thesleevefitsoverthenozzle

swithinthe capnut.Aftertightening

oved.»

testerandreset.

ENGINE

zzlerecessinthe cylinderhead

zleholderassembly.Particularatten-

seatingsurfacesinorderthat no

illcausetheassemblyto becockedor

bustiongases.Nohardor sharptools

eaningoperation.Aroundpieceofwood

veryeffective.

torgaskets.Itis essential

keson thesurfaceswhichthegasket

carefullyinsertedsothat the

againsttherecesswall.

nutsshouldbetightenedevenly

ocockingofthe unit.

relinesand leak-offlines.Make

tightened.

TION

irectlyontothefuel pumpand

pshaft.See Figure199.Thegovernor

tothefuel meteringrackbymeans

corporatingasmokestop.

sticsareobtainedbymeansofa

ghtforcewithahelicalextension

ssetby themeansofspringadjust-

yofregulationisadjustablebyvary-

ofthespringfrom therockershaft.

hespeedandfor generatorsynchroni-

ph65, andinparagraph06instructions

opare given.

ON


/ h t t p : / / w w w . h





ubricatedbyfillingthe governor

thebottomof thebodywithagood

ure 199.Theinternalpartsare

hegovernorgearsand fromtherotating

ORSPEED

W.Setthegovernorto 1800R.P.M.

ustingscrewshownin Figure321.Re-

ircuitbreakerto"Offposition.The

nthetachometershouldbe1845.If not,

ndturnthe surgeadjustingscrew1-1/2

speedisover1845,andout (left)

11. Againapplyloadandsetthe

ownin Figure321.Againdisconnect

erfor1845R.P.M.NOTE:Itmaybenec-

oingprocedureseveraltimesto obtain

ssaryforparalleloperation.Install

View,ShowingSmokeStop

OP

W.at1800R.P.M.Loosenlock-

owninFigure211so therackisforced

tiltheenginejustbegins toslow

andreplacelid.


/ h t t p : / / w w w . h





UOF

rend

ed

ernor

dfrom

orlid

efour

g,as

PLING,

NECTION

Y

derShaftAssembly.

ftandbalanceassembly,asshown

removedthegovernordrive gear.

dplate bearingispressedinand

Y

Y


/ h t t p : / / w w w . h





urgebolt, shownInFigure214.

expansion,plugat theendof

vernorhousing,asshowninFigure215.

NECTION

veryokeandshaftassemblywith

wninFigure216.I fnecessarytoreplace

blyas thesepartsarecarefully

gularityatthefactory.Removethe

aftbearingfromthehousingshownin

ershaftconnectionandnut,thebear-

e floatingouterraceshowninFig-

EMBLY


/ h t t p : / / w w w . h





Y

er bearingwithanarborpress

eweightpin toremovethespider

ure220.

sassemblethebalanceofspider

eneeded,it isadvisabletoreplace

elocknutandsmoketubeandpush

nk.

emovetheendplateunless the

obereplaced.Ifnecessarytoremove

fivemountingscrews,showninFigure


/ h t t p : / / w w w . h




D

ernorEndPlateto FuelPump.

LACEMENTOFGOVERNORPARTS

welchplugs.

anysign ofpits,wear,orrough-

heforegoingconditionsexistson

hedrive gear.

sforexcessivewear;if worn,re-

n pairs.

opLinkandStopTube.

91


/ h t t p : / / w w w . h




duewear.If worn,replacethe

assembly.

ftassemblyforloosenessofthe

replacetherockershaftassembly.

GOVERNOR

ed,shellacandinstallanewgas-

singandgovernorhousingendplate,and

n Figure221.Withapunch,stake

untingscrews.

showninFigure222.

e presenttime-

ve

d

-

he

y

ack

nd

ss

ce

ew

nt

e.

.

s

the

GRACE


/ h t t p : / / w w w . h




edsettingandsmokestoptobe

.Seeparagraphs65and66.

htwofuel filters,aprimaryfuel

ilter.See Figure197.Because

gasoline,theycontainmoregum,fine

eventthesefromenteringtheengine

maryandsecondarystageoffiltration

ldthesefiltersbe servicedasrec-

econnectionsshouldbethoroughlyin-

ulandreplacedifthereis anyevidence

ngdowninternallyeitherfromage

reakdownwouldreleasefineparticles

ARYFUELFILTER

nt,thoroughlycleanthehousing,

ment.

tom

he

o

.

out

nd

NDARYFUELFILTER

ris sealed.Duringtheover-

with asimilarsealedfueloil filter.

unscrewtheplug atthebottomto

water.Replacetheplugandunscrewthe

ethefueltransferpumpto bleedtheair

placeevery512hoursofoperation.

40,theair cleanerispartofthe

everitsfunctioniscloselyrelatedto

fore,theinstructionsforservicing

ongwiththefuelsystemcomponents.

leanerto preventabrasivedust,

engine wear,fromenteringtheengine.


/ h t t p : / / w w w . h




TEM

aneris oftheoilbath type.The

terelementbeforeitentersthe com-

gine.

tefficiently,theaircleaner

.Theconnectionsbetweentheair

ldmustbekeptair tightatalltimes.

vibration,theclampshouldbechecked

operation.Theoilcupshouldbe

efilledwithoilto theoillevelbead

8 hoursofoperation.

ptionallybad,itmaybe wiseto

freshoileveryfourhours.The

cuptotheintakemanifoldadaptor

methecupis removedrorcleaning.

terevery64 hoursofoperation,

assemblyshouldbesoakedingasoline

essedair.Ifdirt conditionsare

vicingshouldbedoneeveryeight

ompressionignitionengineneed-

ombustiblegases,theelectrical

marilytosupplyenergyforcranking

uch electricalcontrolsasthesafety

dsafetyshut-offvalve.Thecranking

artingmotorwhichreceivesitselec-

agebatteries.Thesebatteriesare

generatorincombinationwiththevol-

maticallydecreasesorincreasestherate

tteriesdependinguponthe stateof

m,Figure226.

m(Engine).


/ h t t p : / / w w w . h





ERATOR

maticallycontrolledbythelubri-

he heatofthewaterin thecooling

rops belowsevenpounds,orifthe

ds205° F.,theelectricallyoperated

ticallyshutofftheenginebyshutting

oughthesolenoidvalve,thusstopping

uel injectionpump.

ergy

h

era-

es-

cuit

ator.

to-

nd

the

OilHole

ure 227.Generator

f(AutoLite).

atorisnotrunning,thecontactsare

isstarted,thecontactsare automat-

egeneratortothebattery.Whenthe

eneratorlosesspeed,thevoltagefalls;

torvoltagedropsbelowthebatteryter-

tsautomaticallyopen,thuspreventing

ngbackthroughthegenerator.

cesthegeneratoroutputwhenthe

huspreventinghighvoltageandover-

hebatteryisin alowchargedstate,

yincreasesthegeneratoroutputtoits

batteryreachesahighstateof charge,the

ecreasestherateofcharge.

RATOR

vicingswhichthemaintenance

vethegenerator.Theyarethe 128

56hourtune-upandthe 512hourover-

NSPECTION

andinspectthecommutator.Ifthe



/ h t t p : / / w w w . h





ERATOR

paperagainstitwhileturningthe arma-

outof thegeneratoraftercleaning

re

or

m-

ara-

shes

mu-

hes

t

r

of j

ved"

ven

m thegeneratortotheregula-

to thebattery,andfromthebattery

rayedinsulation,brokenwires,and

ections.Repairorreplacethedefec-

ximumoutput(approximately1800

mutatoraction.Ifthereisexcessive

esandcommutator,removethegenerator

accordingtoparagraph78.Inspect

iringasindicatedin"C.",paragraph

tetheammeteraction.Slowly

.Theammetershouldshowagradually

hebatteryis fullycharged,thecharg-

entheoutputapproachesitsmaximum.

arged,thegeneratorwillcontinue

mrate.Iftheregulatordoesnotoperate

egivenatune-upinspectionasgiven

ngsofthegeneratorshouldbe

mediumengineoilinthehinged top

head.Fillthecommutatorendoil

neoilinthe combinationoilerinthe

er.

romtheengineandtakeoff the


/ h t t p : / / w w w . h





ERATOR

randifit isdirtyordiscolored,

eof00or 000sandpaperagainstthe

thearmaturebyhand.Blowthesandout

ningthecommutator.Ifthecommutator

eratorshouldbedisassembledandcom-

dingtoparagraph82.

d

d

nin

tthe

g

e

that

sh

kthe

atthe

the

the

the

ouldbe

edas

.

ator.

per

bra-

r

nd-

urof

ecer-Figure230.Disconnecting

BrushLeads.

.Donotgrindexcessivelyandbecare-

ofthebrushes.SeeFigure231.

ension.Hooka springscale

neartheendor intheholein thelip

dpullona lineparalleltothe faceof

gjust asthearmleavesthe brush.


/ h t t p : / / w w w . h





ERATOR

ionshould be53ounces,maximum.The

houldbe 50to60ounces.If the

rushesandthecommutatorwillwear

GENERATORBENCHTEST

eneratortothebenchtest,re-

orbytakingoutthe regulatormounting

theregulatorleadsasshowninFigure

-

sh

eter

al

olts

ch

m-

ble

e

era-

eandconnecta voltmeterfromthearma-

rframe.Adjustthevoltageat13.0.

lowly,andtheammetershouldshow 3.89

entis notwithintheselimits,it

onnections,wornbearings,orpoor


/ h t t p : / / w w w . h





LTAGEREGULATOR

tbe doneonthetestbench,the

ontheengine.)

thegroundandconnectan

matureleadandthebattery.Connecta

ureleadtoa groundonthegenerator

atorandincreasethespeedslowly,

gingrateobtained.Thischargingrate

figuresgivenasfollows:

eres,maximumoutput.

peres,maximumoutput.

tput,advanceorretardthe third

etothe baseofthebrushholder.

STINGVOLTAGEREGULATOR

dberemovedfromthegeneratorand

thefollowinginspectionand adjust-

yleadstopreventshort circuiting.

overandinspectthe regulator

fburningor abnormalhightempera-

s,insulation,externalterminals,or

onnectionsresulting frompoorsol-

hebottomofthemagnetcores;(4)

TE:All nutsandscrewsmusthavelock-

eredcarbonresistor.Repairor re-

ntionedabovethatmaybefaulty.

theyaredirtyorburned,they

ceofcrocuscloth.See Figure233.Do

e.|

s

ble,

t

ce

ng

ove

NG

c-

f

en

the

be-

99


/ h t t p : / / w w w . h





ERATOR

kwasherfromthearmatureshaft.

eadband.

ethird brushandtheinsulated

gure230.Liftthebrushesoffthe com-

ure229.

crewsatthecommutatorend.Slide

offthegenerator.

ve endhead,andthepulley

gure235.

th

or

ATURE

nces

-

make

ck

with

st-

toa

h

surface)andtouchtheotherprobeto

nt,asshowninFigure238.Donottouch

ommutatorasan arcwouldmarthe


/ h t t p : / / w w w . h





ERATOR

recoilor commutatorsegmentis

ht.If thegroundisaccessible,it

wisereplaceagroundedarmature.

shortson agrowlerasillustrated

e

by

ach

d

e

unt

g

t

th

ut

rom burrs.Themaximumeccentricity

exceed.003".

MEANDTHEFIELD

the fieldcoilsandleadsand

specttheleadsandterminal posts

ationorpoorlysolderedterminals.


/ h t t p : / / w w w . h





ERATOR

e

n

nd

gine

-

Do

mbled

DHEAD

full

e

noil

ead.

LYOF

an

gure

g

tly

the Figure24-3.Pressing

reArmatureIntoDriveEnd

ce.Head.

torendheadontheframeand field,

s inplace.

eframescrews.Besurethat the

eld connectioninsulation.SeeFig-

their holdersandconnectthe

tthe brushesareassembledsothat

mmutator.Ifthebrushes neededre-


/ h t t p : / / w w w . h





ERATOR

beensandedaccordingtotheinstruc-

8,step E.

the commutatorendhead.See

onafter assembly.

oilto thedriveendoilerand

pockettothe combinationoilerand

eratoraccordingtoparagraph79.

uldbesubjectedtothe testsgivenin

RESISTANCETESTS

ivenforthe voltageregulator

ingregulatortestsshould beincluded

haulperiod.

erand-checkitsresistanceonan

ween2.75and2.85ohms,replacethe

omthe"A"terminaltothe regula-

atorifthis resistanceisnotbetween


/ h t t p : / / w w w . h





R

ESTS

0"to .030".

he contactsclosedandisadjusted

stationarycontact"A"inFigure234.

.

045"to 4.001".

he regulatorcontactsclosed.It

or loweringtheuppercontact"C"in

orcontractingthebridge"D"holding

POINTGAP

5"to .045".

aturestopin Figure234.

005"minimum.

camEinFigure234.

nedto cranktheenginewhenthe

ircuitbetweenthestoragebattery

246.It consistsoffivemainsub-

eframeandfield,thearmature,the

epinionhousing,andtheBendixdrive.

whichthemaintenancepersonnel

or.Theseservicingsarethe 128hours

6hoursofoperationtune-up,andthe

rhaul.

MOTOREVERY128HOURSOFOPERATION

andinspectthecommutator.Ifthe


paperagainstitwhileturningthe arma-

outof themotoraftercleaningthe

utatorisroughorworn,themotorshould

neforan overhaul.

ON


/ h t t p : / / w w w . h





R

ebrushesshouldslide freelyin

contactonthe commutator.Makesure

tlyin linewiththecommutatorseg-

edrepair orifthebrushes areworn

originallength,themotorshouldbe

sgivenin paragraph100.

hebattery tothegroundand

artingswitch,andfromtheswitchto

rodedconnectionsandforfrayedin-

ofengineoilto theoilerin

.

and startingswitchtoseethat

ndthatthe leadsareproperlyconnected

eoperationofthe unitsandremove

onifthe operationisnotsatisfac-

MOTOREVERY256HOURSOFOPERATION

otorfromtheengineand takeoff

r,brushes,andwiring,andadd

neoiltothe oilerinthecommutator

heholdersasshownin Fig-

re248.Removing

pinionhousing screw.

dingthepinionhousingto theframe

rmatureofftheframe.SeeFigure248.

he pinionhousingwithanarborpress

osenthe Bendixshaftspringscrewas

de theBendixofftheshaft.SeeFig-


/ h t t p : / / w w w . h





R

atureshaftinkeroseneand lubricate

ectthe Bendixforwornpartsor

eanyfaultyparts.

thearmatureshaftmakingsure

ace.Tightentheshaft springscrews

nthe armatureshaft.

andsoak thebearingsinmedium

ousingonthe motorandfastentothe

e248.

offShaft.


/ h t t p : / / w w w . h





R

LOADTEST

bonpilerheostat,andbatteryin

naland theframe.(Startingmotor

eenginefor thistest.)Connectavolt-

inaltothe motorframe.SeeFigure252.

LoadandTorqueTest.

voltsand readtheammeterwhichshould

mperes.Holda tachometeragainstthe

haft andreadthespeedwhileoperating

ouldbe atleast4000R.P.M.

espeedlow,inspectthe bear-

andmakesurethe armatureturnsfreely

ecurrentislow,inspectthe brushes

ommutatorandinspecttheinternal

orhighresistance.

CKTORQUETEST

asgiveninthe foregoingparagraph

leandtorquearm,measurethestalled

urelytothe startermotorshaft.

pedrigidto aworkbench.Hookthe

armexactly12"fromthecenterofthe

entflowingthroughthemotor adjust

readtheammeterandspringscale.

amperesmaximumandthe torqueshouldbe

If thecurrentishighor thetorque

forhigh resistanceconnections,in-

t,andincorrectbrushseating.


/ h t t p : / / w w w . h





R

6HOURCHECK

don thecontrolpanelandthemag-

arecontainedinthe controlbox.

epressed,oneofthesolenoidswitches

onnectsthestartingmotortothebattery

ance.Thisresistancereducesthelarge

oughthemotor.Whenthe motorbegins

elayoperatesand excitesthesecond

sswitchclosestheresistanceis

tteryvoltageisappliedtothe start-

GSWITCH

tchfromthecontrolpanel.

udsand removethecovernuts.

pecttheleads,insulation,and

reaks,orimproperandlooseconnec-

for looseorcorrodedconnections

coverandassembletheterminal

hepaneland connecttheleads.

SWITCH

thecontrolpanel,connecta

o3/8"-16terminalsof thecontrolbox.

ormal mannerandreadthevoltmeter.

rgerthan.05voltsper 100amperes,

uringnormalstarting,thestarting

elyoverhauled.Seeparagraphs110and

ATIONOVERHAUL

hemotorandtakeout theflange

betaken tothebenchforan overhaul.

ARTINGMOTOR

heholder.SeeFigure217.

orandheadholdingscrews.Take

e Figure253.

ingandthearmatureoff the

ON


/ h t t p : / / w w w . h





R

with

n

e

e

MATURE

dcommutatorforevidencesof

nandsolderingtomakesure thatall

order.Makesure thecoilsarepro-

tatorandcoreslots.If theshaftor

atureshouldbereplaced.Ifitis nec-

ommutatorinalathe,takeonlyalight

ntedonthe bearingseatsandnotonthe

burrsfromthecommutatorandundercut

ndsquaretoa depthof1/32".

ounds.

ft

tor

other

h

or

sh.

e

n

el


/ h t t p : / / w w w . h





R

eel

r

RVICING

g,

akeFigure256.Testing

r-for ShortsonGrowler.

edandarefreefromcorrosion.To re-

unsoldertheleadfrom thebrushcon-

d intheconnector.Insertthenew

nthe lipandclinchtightlybe-

lderingjobmustbe donetoprevent

uetoa poorcontact.Seatanew

257accordingtotheinstructionsin

terminalposts forgrounds

amp.Makesure thebrushesare

onnections,andtouchoneprobeto

otherprobetotheframeas illus-

oundispresent,the lampwill

heterminalpost andtheotherprobe

shes,asillustratedinFigure259.

ampwillnotlight.


/ h t t p : / / w w w . h





R

rame

ss-

me.

ce

escrewsandremovethepole

igure260.Inspectthe fieldcoils

eckforopenswiththe testlampand

ssarytoreplaceanyfieldcoil,

areclinchedtightlyandsolderedpro-

lsinthe frame,usingpolepiece

pedinboiled linseedoil.Afterthe

heframea fewshortblowswitharaw

lepiecesproperty.

ostandwasherand againcheck

ndopenswiththe lampandtestprobes,

RVICINGTHECOMMUTATORENDHEAD

olderplatefrom thehead.See


/ h t t p : / / w w w . h





R

t wickfromtheheadandtakeout

.Clean bothplatesthoroughlyand

cracked,replacetheplates.Inspect

tion.Checkthebearing.If itis

eit.Usetheproperarbortoinstall

osecuretheproperbearingfit.Re-

aged,andreplacethebrushholder

orspringsarecorroded,distorted,

ts inmediumengineoiland

Makecertainthatthedrain holein

mofthe head.

bes,checkthebrushholdersfor

hholderplate,ifa groundispresent.

RVICINGPINIONHOUSING

ectit forcracks.Checkthebear-

ifwornexcessively.Usethecorrect

ingtosecuretheright bearingfit.

mengineoil.

RVICINGBENDIXDRIVE

eBendixdrive.Inspecteachpart

placeanyfaultypartand lubricate

engineoil.NOTE:Usenew lockwashers

sembled.

RVICINGTHEINTERMEDIATEBEARING

aringendplateandinspectfor

theplateorbearingif necessary,

stall thebearing.Soakthebearing

ARTINGMOTOR

elthrust washersonthedriveend

ssemblethe intermediatebearingon

toiltothe armatureshaftand

eontheshaft.See Figure251.Make

sarein theirproperplaceandtighten

Bendtheearsof thelockwashersto

osening.

nthepinion housingandturnthe

thedowelpin fitsintotheslot.

tedownagainsttheshoulderin the

andpinionhousingon theframeand

ding screws.Tightenthescrews

sonallscrews.SeeFigure248.

ON


/ h t t p : / / w w w . h





twasherfor controllingend

dofthe shaft,andthenassemblethe

torendheadonthe motorandfasten-

.Assemblethe brushesintheir

avebeenreplaced,theyshouldbe

structionsin paragraph78,step"E",

RHAULEDSTARTINGMOTOR

the brushesonthecommutator.

ectlyinlinewith thecommutatorseg-

ndreplacethebrush holderplate.

asurethespringtension.Hook

springattheend andpullona line

brush.Takethereadingjustas the

thereadingisnotbetween40 and50

andtwistthespring holderwithpliers.

brushesfromtheholdersbeforeremoving

ge,

een

ner

ture

s.

x

1.

f-

ear-

t

ove

and

one

k,

diumengineoil totheoiler

d.

orto theno-loadandlocktorque

raphs95and96.

TONSTARTINGSWITCH

vedfromthe panel,

r groundsandopens.Touchthe

testprobeandtoucheachterminalin

s showninFigure262.Ifthe lamp

groundandshouldbereplaced.


/ h t t p : / / w w w . h





ITCH

e

k

thold

s.

RVICING

G

aks andimproperlysoldered

replaceorrepairany thatarefound

torforcracksand checkitsre-

eplacetheresistorifit iscracked

thin13.5to 16.5ohms.

nceunitand replaceitifit

leantheunitthoroughly.

dwashers.Replaceanythat

nspecttheterminalsat thestuds

rrosionandreplaceanythat cannot

actoryservice.

nectionsforlooseterminals,

dedconnectors,andfordefectiveleads,

fanyof theseconditionsarefound.

OIDSTARTINGSWITCH

tanceinserieswith#10 -32

itch,theswitchbase,andthe 12volt

eterontheswitchterminaltothe base.

y,notingthevoltmeterreadingwhen

tedbya click.Reducethevoltage

gvoltage.

snot closeat7.0to9.0 volts

o2.0volts.


/ h t t p : / / w w w . h





ITCH

y,carbonpile,and a200ampere

two 3/8-16terminalsof thesolenoid.

ssthetwo3/8- 16terminalofthesole-

dbasetoonebatteryterminaland

nalto theotherbatteryterminal.

mperesand readthevoltmeter.Ifthe

ngof.05volts,replacethesolenoid

estsonthe secondsolenoid

randinspectthecontacts.Ifthe

ngthwiseandparalleltothe armature

.Cleanthe contactswithastrip

bontetrachlorideandremoveanyresi-

eoftape.Inspecttheinsulationand

ofbreakageorcracks,andreplacethe

gapwitha .034"-.038"flat

endingthe bracketholdingtheupper

y,variableresistance,volt-

psas illustratedinFigure266.In-

ecircuit.Lamp$1shouldbelit.

cenotingthevoltagejustas lamp#1

uldbebetween3.0and 4.0voltsand

lowerarmaturespringhanger.In-


/ h t t p : / / w w w . h





LSWITCH

nincreasesthevoltageatwhichthe

thevoltageslowlyandnotethevoltage

Thisvoltageshouldbebetween0.4to

yvaryingtheheightofthe mainsta-

keepthecontactsalignedwhen

eadjustedas indicatedinthe

acetherelay.

he baseoftherelaywithone

turn withtheotherprobe.If the

oundedrelay whichshouldbere-

minalsmarked"a"and"b"inFigure

redown.If thelampfailstolight,

andthe relayshouldbereplaced.

dclinchtheearsto holditin

controlbox,reversethedisassembly

graph111,andremountthe controlon

TROL

consistsofthesafetycontrol

ve.Thesafetycontrolswitchthrough

obpermitsclosingthecontactssothat

Assoon astheenginestartsand

esafetycontrolmechanismautomati-

obto"run"position,arrowpointing

on,shouldtheoilpressuredropbelow

temperatureinthe coolingsystemgo

lswitchcontactswillopen,causing

ff theflowoffuelto theengine.

rledKnob.


/ h t t p : / / w w w . h





LSWITCH

AFETYCONTROLSWITCH

anbemadeis theoilpressure

rarely havetobeperformed.The

eensetatthe factoryandisnotad-

itchesforreplacementarealsoset

noreadjustmentuponinstallation

heoil pressureatwhichthecontacts

ine,turnthe manualcontrolknobwith

".SeeFigure267.Removetheknurled

ver,thus exposingtheinnerworkings

h.SeeFigure268.Connectpressure

andapplypressureagainstthe

loperatingoil pressureoftheengine

haftautomaticallyturns.Bleed

slowlyuntilthe gaugepressuredrops

contactsareto openstoppingthe

ooccur).Hold pressureconstantat

sionon themainspringbyturning

ght(clockwise)justtothepoint

ngine,theoperatormustturn the

n",placingthecontactsintheclosed

comesuptospeed,the arrowmust

erticalposition.IMPORTANT:Unless

tonormalontheinitial startofthe

eleasetotheverticalpositionto pro-

tdownincaseofoil pressurefailure.

ismfunctionsonlytoopenthecontacts

emperaturerisetothe determinedsafety

ownbecauseofoverheatedcooling

ustdropapproximately40° beforecon-

edforrestartingtheengine.


/ h t t p : / / w w w . h





LSWITCH

fromSealingTube.

tandtwistthe coilslowlyto

be.SeeFigure271.

heleft(counter-clockwise)

d outofthevalvebody.SeeFig-

evalvewill dropwiththesealing


/ h t t p : / / w w w . h





vevibration.Ifthe bladesareonly

traightened.

rifugaltypepumpwhichhasaself-

edsnoexternaloiling.Thispumpis

quiresno adjustment.

MP

of

ss.

eimpellerandbodywith the

eimpellerand sealassembly.See

y

ft,Impellerand

e

-

the

ade:

PUMP

s.


/ h t t p : / / w w w . h





agram.

ternalpassagewhichcarriesoilto

Fromthemainbearings,theoil is

grodbearingsbymeansof adrilled

sreceiveoilthroughtherifle drilled

dersarelubricatedbytheoilthrown

earings.Fromthemainbearings,side

haftbearings.

totheidler gearhubthrough

.Oilfromthehubof thisgearis

edhole inthehuband ispickedup

egearwhereit passesthroughsmall

rimbetweentheteeth,spraying

ofthe enginewithS.A.E.30oil,

onditions,willbeapproximately25to

gs

n.


/ h t t p : / / w w w . h





reenarrangedtorise and

crankcasesothatonly thebest

s.SeeFigure280.

NG,ANDREPLACINGPARTSOFTHEOILFLOAT

loatinunleadedgasoline.Blow

edair.Ifthefouling isbad,straighten

ovetheshield,andcleanthescreen

eshisbrokenor loosefromthefloat

etheentirefloatassembly.Ifthe

eassemblymustbe replacedsincethe

ndreplaced.Whenputtingbackthe

ypositionedandthe earsturned

htheearswith pliers,notahammer.

veljointis freetomovesothat

surfaceoftheoil.

ravel limitinglugs.Makesure

e.Thelugsshould beatrightangles

etube.

ks,

ulicreliefinthecasting.Theoil

trappedbetweentheteethisallowedto

icrelieftothe pressuresideofthe

blepartsin thistypeofrelief.The

earhavebushingswhichweremachined

e teethwerecut.Thegearsandbush-

a unit.Thereisanexpansionplug

.Thisplug isusedasan oilsealat


/ h t t p : / / w w w . h





cessandshouldnot beremoved.The

agesgothroughthetwolocating

PLACINGOILPUMPPARTS

removethesixcapscrewsandoil

ethandthebushingsin thegearfor

thebushingandthegear mustbe

heclearancebetweentheteethandthe

rethan .008",replacewithnewgears

ebacklashasshowninFigure282.If more

ars.Alsoifthe endsofthegearsare not

case,replacethegears andbushings.

hthebushingsrun. Ifthestuds

swithnewones. Examinethecasefor

essary.

mpGear.


/ h t t p : / / w w w . h





MP

idlergearin thehousing.Slip

SeeFigure 283.Setthecoverin

shaftintheidler gearandthenthe

vegear.SeeFigure284.Makesure

inalignmentwiththecoverandbody

tallingandtighteningthesixcapscrews.

rsturn freely.Toavoidhavingto

nstalledonthe engine,fillthe

ation.Wheninstallingpumpbe sure

ts

-

ug

se,

sfour

-

n-

d

o

n-

e


/ h t t p : / / w w w . h





LVE

HE

MINUTE

N.As

sup,

ef

p

epin

e

ve

F

ainan operatingpressureofapproxi-

eed andtemperature.Noadjustment

ishedis oftheproperweightand

tmentcanbemadebystretchingor

owever,anewspringshouldbeobtained

oses itstension.SeeFigure287.

eliefValve.


/ h t t p : / / w w w . h





XCITER

ONANDSERVICINGOF

XCITER

onsincludethedetailedstepsnec-

generatorandexciter,itshouldnot

tetear-downisnecessary.Onlyonrare

arytoteardown thegeneratoras

onsheregivenimply.If,during

nsforinspectionandcleaningare

randexciterlubricatedattheinter-

oroverhaulwillnotbenecessary.See

onareextremelyhot anddirty,

gandsuchotherservicingsasmay be

morefrequently.

RALTERNATORLUBRICATION

terareshippedfrom thefactory

dgradeof greaseinthebearingsto

mately4,096hoursofoperationat

res.Seeparagraph141.Attheend of

hegreaseshouldbe replaced.

EASEFORALTERNATORANDEXCITER

ionofthegeneratorbearings

hemanufacturerrecommendsahigh

No.1 consistency.TheArmyspecifi-

sttothisrecommendedgreaseareNo.W-2

dball bearingsandNo.WB-3forthe


/ h t t p : / / w w w . h





EARINGHOUSINGGREASECAPACITIES

-4 ounces

8"longand 1/8"indiameterwill

ounce.Thiscanbeusedasa guidewhen

dwhenagreasecupof knowncapacity

MPERATURES

dgreasesareonthebasisofactual

er194° F.(90° C.).Ifoperatingand

chthatthebearingtemperaturesex-

reaseshouldbechangedmorefrequently.

nded:

eevery3,072hours.

ASEFROMMAINGENERATORANDADDINGNEWGREASE

orbearingand housinggrease,

0-over2ounces)in thehousingand

minutestoallowtheoil tothinout

ainpluganddrain asmuchaspossible.

e

SIIP

ec-

un

o

t

he

a-

n

-

wly.

t

ng

.If

f

he

hrowgreaseinsidethe generator.

thusthrownfindits waytothecollec-

willseriouslyaffecttheoperation

vencausecompletefailure.

reasegunsshouldbeavoidedif

snoaccuratemethodofdetermin-

eing introducedintothebearinghousing.


/ h t t p : / / w w w . h





XCITER

ps,it issuggestedthatascrewtype

nozzlebeused.Beforeusing,however,

elledperturn ofthegreasegunscrew

greasecupof knowncapacityis

wedintothefiller pipeandused

ASEFROMEXCITERBEARINGHOUSING

ofthefull sealedtype,requires

tmentinremovingtheoldgreasethan

generator,oralternator.

ghasnodrain.Therefore,the

ovedandthegreasewashedfromthe

ithcleanunleadedgasolineorkerosene.

h outtheballbearing.Afterthe

letelyfillthebracketcavitywith

iterEndBracket,showingLabyrinthGroove.

ERNATORRINGS,EXCITERCOMMUTATOR,AND

ectedforwear,properspring

heholders.If thebrushesarestuck

ubstances,theyshouldberemoved


/ h t t p : / / w w w . h





XCITER

d

tor.

utator

es

be

om-

d-

nt

the

tator.

sily

ermay

inst

ator,

e

3.

ator

st

ol-

e

orsandpapershouldbemovedbackand

alleltothe shaft,withtheengine

e speed.NOTE:Besurethatthe

ecommutatorduringthis operationto

wearandparticlesoftheabrasivebecom-

eof thebrush.

movedfromtheundercuttinggrooves

ardwoodshapedtothe widthofthe

aper.Alsosuitableforthisoperation

defromwhichthesethasbeenground

awblade,however,exercisecareto

mutator.Afterthecommutatorhasbeen

orandbrushfacesshouldbecarefully

twhichmightcutor scratchthecommu-

THSHOULDNEVERBEUSEDONA COMMUTATOR

INGS(CollectorRings)

htherings,all thebrushesshould

sarybrushwearand topreventthe

mingimbeddedinthesurfacesofthe

sbe keptcleanandwellpolished

non-lintingmaterial.SeeFigure292.

escriptionshouldbeusedonthe

ringsbecomeroughor pitted,

edby polishingwithapieceofsand-

ntpiecehasbeencut havingthesane

toneisnotavailable,thensand-

sing againstthesurfaceoftheslip

shapedlikethesandstonementioned


/ h t t p : / / w w w . h





ings.

3.

e

t

-

er

sh

y

eany

t

s.

PRING

dto

t

d

less

sh

s

aced.

a

es.

nsionindefinitelyunlessthebrush

rmitsthebrush holderspringtocarry

nd thespringpressurefallsbelow

uldbe replaced.

re,hookasmall springscale

ximately1to2 poundsunderthebrush

hereitbearsonthe brush.Pullthe

edirectionof thebrushtravelin

nthe fingerisjustlifted offthe

bemade.

ATINGBRUSHES

eexciteroralternatorareworn

nallength,theyshouldbereplaced.

ewbrushes,thebrushshouldbe

pRings

ofWood.

3*


/ h t t p : / / w w w . h





XCITER

rnatorandExciter

nder normalbrushspringtension.

ndpaper,withthesandedside against

ofrotationfollowingthecontour

rorthealternatorslip ring.See

ryclothontheslip rings,the

es.

donewith#0or#00sandpaper.

minutesand inspectthebrushcontact

g.Ifnotperfectlyseated,repeat

th#0or#00 sandpaper.

mportantthatthebrushesofboth

bereplacedwiththe sametypeand

hemanufacturer.

NDEXCITER

beobservedindisassemblingthe

torhasbeenremovedfromthe engine

nsgiveninparagraph2:

torcouplingandremovetheventi-

couplingdiscs,hub,andflangeto

tionsinorderto reassemblethemin

eFigure288.

wsfromtheflangeandremovethe

ON:Leaveatleastonebolt andnut

plingdisctopreventthe discsfrom

8.


/ h t t p : / / w w w . h





XCITER

Y

rnatorandExciter

ngefromthealternatorshaftas

onthe flangehub.Ifhubdoesnot

orapidly heatflangewhileengaging

N:Donotletflametouchthe shaftand

ws:(RefertoFigure294.)

eadsfromthecollector

breakingopentherheostatleadwhich

torframeintothe terminalbox.Remove

idethealternatorend bracket.

hboltnuts attheexciter

aringcapscrewsattheex-

nowberemovedbytapping

adwiththe aidofablunt tooland

d brushholderassembly

reafterraisingthe exciterbrushes

xciterleadsthatpassthroughthe

connectiontothecollectorrings

oughtheopeningto preventdamaging

unduestrainson theconnections.

nnowberemovedbysimply

lleltothealternatorshaft.

endbracketafterfirstlift-

esand removingthefourendbracket


/ h t t p : / / w w w . h





ernatorball bearingcapscrews.Tap

e beadbyusingablunt tooland

etoffevenlytoavoidpinchingatthe

ghousing.

nowbe removedfromthe

outfarenoughtoattacha widesling.

aybeconsideredassubjectto damage.

etakentoavoiddamagingthecollector

dcoils,etc.Thebesttypeof sling

bandwhichshouldbeslippedunderthe

erotor.Thisshould bepositioned

otoriscarriedon atleasttwoofthe

isusedaroundthe shaft,aspreader

depressureagainsttherotorbalance

castironandwill breakeasily.

ngeneratorandexciter,reversethe

tthe couplinghubinoilto

feasible,useatorchon thehub,

eat,coattheshaftwith whiteleadto

hehubonto theshaft.Installthe

hemup withthemarksonthehub.

ngcertainto lineuptheflangewith

discs.Thesemarksweremadebefore

useapieceof softcoresolder

approximately400°-Heatthehub up

derbeginstomelt.

SEMBLIES

R

soldasadisassembledunit,

isassemblyofthis member,except

enthis becomesnecessary.Winding

efoundunder"WindingandConnection


/ h t t p : / / w w w . h





BLY

wofMainGeneratorRotor.

RASSEMBLY

ng:

bly

y

s

er

emberisas follows:Removethe

thetongueoftheball bearing

vein theballbearinglocknut.The

ighthandthreadcanthenbe backed

orBallBearing.


/ h t t p : / / w w w . h





ULLER

KS

EFLANGEHUB

ANDREPLACE

LLOCATION

orBalanceFlanges.

eremovedbyusinga pullersimilarto

00.Thepuller hooksshouldengagethe

gthebalanceflanges,besureto

eoriginallocation.Failuretodo

beingoutof balance.

IELDCOIL

connectthesquirrelcageslip

wedgepinby drivingouttoward

ressandpressoff thepole

oftherotor.Pressureshould be

ilof thepolepiece,usingapunch

piecedovetail.Donotattemptto

pressingagainstthepolepiecebody

edgingactionwhichpreventsthepole

eldcoilcannow beremovedfrom

ACKETANDCOLLECTORRINGBRUSHHOLDER

ecessaryonthealternatorendbrack-

orringbrushholderassemblyonthe

Thisassemblyismountedwithfour

ecollectorringbrushholderssee

rush

301.

43


/ h t t p : / / w w w . h





CITER

t

d

k-

e

n

mage.

be

with

at

tly

to

r-

e.

m-

g-

e

gh

e

screw

ap.

CITERFRAMEANDCOIL

interpolesareeachheld in

wswhichpassthrough theexciter

holesinthe polepieces.Thesescrewsare

ngaportion oftheframemetalinto

crew.Beforeattemptingtoloosen

l thereforebenecessarytoremove

screwheadslot.

sregulatedbyshimsof varying

pieces,therefore,itisabsolutely

ofshims benotedbehindeachpole

tthesesameshims canbereplacedwhen

apforbothshuntand interpolesis

mainpoleand twointerpolecoils.

cedin theframesothattheyare in

heinterpolecoilsare placedatthe


/ h t t p : / / w w w . h





XCITER

exciterframearenotdrilled

oilsintheframesothat thecoilleads

rmountingbosses.

eadsshouldbesecurelytiedto

trainwillbe exertedontheconnec-

CITERBRUSHHOLDER

ndyokeassemblyis composedof

iesmountedoncanvasbase,phenolic

etedtothecastironbrush holder

geable,

ed

and

.The

-

-

Ad-

on

pring

ew

t

ation,whilefacingtheadjustmentend

verslot isprovidedintheend of

mentpurposes.Springtensionshould

reewiththe springtensionlimitsof

thodofCheckingBrushSpringTension".

TERNATORBRUSHHOLDER

rassemblyiscomposedoffour

emblies.Twoassembliesaremountedon

securedby acuppoint,slotted-head,

npositionwith alockingnut.

tbronzeandare machinedand

onzebrush holderfinger.Thebrush

sarecastintegralwiththebrush holder

ngeronthesupportingshaft witha

brass wirethroughthesmallhole

nbylocatingthe freeendofthe

notchthatwill giveatensionof7

dofAdjustingBrushSpringTension".


/ h t t p : / / w w w . h





HolderandYokeAssembly

hHolder


/ h t t p : / / w w w . h




XCITER

unton astripofcanvasbase,

teelflatwasheron eithersideand

nuts.

LES

lsofthealternatorareun-

inthe alternatormaynotrenderthe

esultin shocktotheoperator.The

nis tolocatethegroundwiththeaid

est. Thegroundwillshowupin the

.Thisisespeciallytrueif the

thecoilheads.A groundinthe

p inthismanner,therefore,itmaybe

rnalstarconnectionandcheckeach

e.Ifthe groundislocatedinthe stator

cessarytostripandrewindthe

practicaltorepairawindingwhich

egnatedwithpolymerizingvarnish.

maybedeterminedbyconnecting

t lampsconnectedinseriestothe

the othersuccessivelytothestator

oroperatingatnormalvoltage.Light-

hepresenceofoneormoregrounds.

ancegroundsmaybedeterminedby

eviouslydescribed,exceptbytheuse

asurementandwiththemachinenotrun-

otorcircuitmay bedetermined

thatthere isnogroundin the

nitat normalvoltageandconnecting

ighttothe frameandtheother

thetwocollectorringbrushholder

ZO

G.

nectionforLocatingGroundedCoil.


/ h t t p : / / w w w . h




XCITER

ampindicatesaground.Tolocate

or, connecta120voltlampin series

ge,using oneterminalofthelamp

neastest loads.SeeFigure306.

orcoil,first openthecircuit

tbetweenoneofthe coilterminalsand

htingofthelampindicatesagrounded

theoutsidesurfaceofthe coils

ected,thenit isadvisabletoreplace

checkrotorbalancebeforereassem-

necessary.

OILS(Failuretoobtainfull ACvoltageon

l)

confusedwithexcitertroubles

r.(SeeExciterTroubles.)

orpartial,in onerotorfield

encedbyuniformoverheatingofthe

oloperationofthe shortercoil.

cuitcanbedeterminedbyimpressing

y120volts(ACor DC)acrossthecollec-

e voltagedropacrosseachcoilwitha

findividualreadingsshouldnotexceed

ortedcoilwillshowadrop lessthan

endingupontheextentof theshort.

excitercircuitisdisconnected

eforemakingthis test.

TORCOILS(Novoltageregistersonvolt-

dcoilwill resultinthefailure

pavoltagein spiteofproperexciter

Testforopencircuitusing thetest

306"bytesting betweenthetwocoil

.Failureofthe lamptolightindi-

uited.

rfield coilsisnotrecommended

sofemergencysincetheentirerotor

efore,anychangeinweightatagiven

beoutofbalance.Forthis reason

o checktherotorbalanceinadynamic

coilreplacementsarenecessary.

eostatturnedfull-out)will

mumvoltagesatfullalternatorfield

ON


/ h t t p : / / w w w . h




XCITER

old

prox.)

t6.0G(approx.)

rrings.Fornoloadreadingraise

nthe brushholderpocketssothatno

brushandring.If voltagevaluescon-

aboveareobserved,checkasfollows.

orts;this canbedonebycheck-

seachof thetwoshuntcoils.The

ngwillbe thefaultycoil.Abadly

olandthe goodcoilswilloverheat

orts;symptomsusuallyare,spark-

enedcommutatorandburntbars. Ifbadly

otpickup afield.Inthis event,re-

eckinagrowler.

encircuits;symptomsaresimilar

b")exceptflashingatbrushesi sapt

companiedbya ringoffirearoundthe

estheexciterwillfailto pickupa

polecoil;symptomsaresparking

htlylowerthan normal.Locatefaulty

gthevoltagedropacrosseachcoil

er.Theshortedcoilwill havethe

tting;theindexpointer should

konthe brushholderyoke.Symptoms

shesandslightly abnormalexciter

shesmaybestuckin theholders

kegoodcontactwiththecommutator.

ctlyseatedto thecontourofthe

ENERATE

eldoesnotregistera voltage).

uredattheexciter,checkas

shesoffthe commutatoranddis-

romtherightbrush holder.

dforopencircuit.Usetest

betweenthe righthandbrushholder

inalmarked(RHEO.-Fl)locatedinthe

openthe lampwilllight.

49


/ h t t p : / / w w w . h




XCITER

ncircuit bytestingwithtest

etwo rheostatterminals.Failureof

statis opencircuited.NOTE:Dis-

eof rheostatbeforemakingabovetest.

befor openingsafterdisconnect-

erminals.Testwithtestlamp(Figure306)

sideterminalsof thetubeinsidethe

reofthelampto lightindicates

atorforopen circuits.See

heBudaCompanyandGeneralElectric

ushesshouldmakegoodcontact

kfreeinthe brushholderpockets.

GEXCITERBRUSHNEUTRAL

must besetonthe neutralpoint

toryperformance,commutation,and

atorlife.Ifit becomesnecessaryto

erarmaturethe brushneutralposition

etif necessary.Thefollowingisthe

s instanceduetothedesignand

andis knownastheInducedVoltage

drequiresthe fieldcircuittobe

urecircuitandseparatelyexcited,and

pin thearmatureobservedonalow

necteddirectlytothebrushes.Proceed

maturecircuits bydisconnecting

rush holdersandremovingtheconnec-

ircuit terminalsinsidethealter-

locatedattheextremetopand is

e Figure307.

sofConnection.Links.


/ h t t p : / / w w w . h





XCITER

falow readingvoltmeter(having

0volts)directlytothepigtail ofone

ofthecommutatorortothebrush

R

E

USH

ramforBrushNeutral.

ntfieldleadsF2 andRHEO-F1

rrentsourceofpowerhavinga poten-

olts.Thiscircuitshouldbe provided

breakingthecircuitquickly.SeeFigure

oneoftheleads connectedtothe

cket.ShuntleadRHEO-F1islocated

box.SeeConnectionDiagramFigures

d maintainthefieldfora

s thoroughlysaturated,andthen

ndobserve,accurately,thedeflection

eedle.

directionof rotationfora

mmutatorbarsandrepeatthe operation

hisprocedureuntilreadingshavebeen

he distancearoundthecommutator.

reached,thevoltmeterwilldeflect

fthezero, withequalintensities

flectionsto therightandleftof zero

henumberoftestpositionsinvolved

e-halfrevolution.


/ h t t p : / / w w w . h





XCITER

WINDINGDATA

.3

ars..57

toBar2

ng.

° C

ogetheratcoil heads(frontand

e1/2overlapping.Insulatecoilleads

ot insulationdetails.

N\

KNCslI

>B

C.KPAPER[

IRON/

TMENT

ofExciterArmatureSlot,

ation.

NT

darmatureanddipwhilehotinblack

merseduntilbubblingceases.Drain

ntilthoroughlydry.Repeatprocess

53


/ h t t p : / / w w w . h





XCITER

INGDATA

mvar

4

3.5

of#24

..

24nexttopole.

NTOFEXCITERCOILS

cklyinblackbakingvarnish,

at225° -250° F.untilthoroughlydry.

plyone'coatof airdryingvarnish

nthe frame.

oilinsulationdetails.

F

AO

UICK-

ATMetMTOF

wThroughOneHalfof

ddipwhilehotin blackbaking

keat225° -250° F.untilthoroughly

.Give coilonecoatofairdrying

edinframe.SeeFigure312.


/ h t t p : / / w w w . h





XCITER

EftCOTI

K.PAPER

ATMENT

GE

wThroughOneHalfof

INDINGDATA

.

windnext topole

5Ohmspercoil

6

stoscovered

etailsof bobbininsulation.

NTOFFIELDWINDINGS

oundcoilanddipwhilehotin black

merseduntilbubblingceasesanddrain

° F.for8to 10hours.Repeattogive

ofRedProtectiveSealeraftercoil


/ h t t p : / / w w w . h





XCITER

ORM

OF

N

ICKness

PAPC* AND

BONDED

NCXTTo

ATMENTOr

wThroughOneHalfof

Coil.

RWINDINGDATA

#12

E.

14...Same

.#8V.C.C.

2

sLinetolineon 220volt,60cy.=.0322ohms

e314.

maincoils 6-5-6-5-6-5,thenwind

hthe 5turnmaincoils.Auxiliary

relength with3/16"cottonsleeving.

fauxiliaryis13-1/2feetfor each

cross-overleadswith3/1G"

7"cottontape 1/2overlapping.

inerand topstick1/2"beyond

asecoilsforfull widthandlength

onconsistingofonepiece.015"ragstock

arnishedmuslinbondedtogether.


/ h t t p : / / w w w . h





T

ANCEOFCONTROLUNIT

IONOFCONTROLUNIT

containsthedevicesessential

gineandthegenerator.Itconsists

thecontrolpanelonthe front,easily

,afixedtopcoverandwith openbottom.

he bottombyshockproofingcushions

eengine.Allconnectionstoexternal

ughtheopenbottom.

IONOFPANELEQUIPMENT

sistsofavoltmeterandammeter,a

or,anautomaticaircircuitbreaker,

ment,asynchronizingswitch,anammeter

rfieldrheostat,theenginecontrols,

dgauges.

trolPanel.


/ h t t p : / / w w w . h





HRONIZINGSWITCH

TOR

K

op View.

FINTERIOREQUIPMENT

urrenttransformersfortheline

transformerforthevoltageregulator

oardsformainandsecondaryleadsand

igures317and318.The spare50A.

circuitbreakeris mountedonthe

diagramfor theunitislocatedon

over.Allunitsare deliveredwith

theair circuitbreakerfor00cycle

IONOFOPERATION

sdesignedto controlthe3

hichmaybeoperatedateither oftwo

.P.M.,127/220V.

.P.M.,230/400V.

oltageismadeby movingconnectionlinks

e generatorandontheterminalboard

ngingthepositionoftheslider on

ethevoltageregulatorcase.Engine

paratelytocorrespondwiththe desired


/ h t t p : / / w w w . h





trolUnit.

e100A.trippingelementinstalled

or60cycleoperationmustbechanged

elementwhen50cycleoperationis

6.

REPLACEMENTS

nelshouldnotattempttomakeany

or switchesotherthanthoseindicated

s.Ifanyof theinstrumentsfailto

erand quickertoreplacethefaulty

snecessarybecauseofthefine

uiredandbecausetheInstruments

onsusuallyarenotavailableto the

TECTION

tbreakerisequippedwiththermal

rrenttrippingelement.Thethermal

electedforoperationinanambient

n-adjustableandprovidesovercurrent

or.Theinstantaneouselement,has

efrom350-1100amperesin thecase


/ h t t p : / / w w w . h





ENTSWITCHES

SFORMERS

saresinglesecondarytransformers

secondary.Thecompensatingtrans-

th5A.mid-tapsecondarytopermit

sationatbothvoltagesofoperation.

d isconnectedtothefullwindingon

mid-tapfor50 cycleoperation.

withacurrenttransformer.The

withtheammetermusthavethesame

whichit wascalibrated,asindi-

n thescaleoftheinstrument.See

eventofafaultyinstrument,it

ewone andthefaultyonereturnedto

entandskill isavailabletomakere-

auseoffaultyinstrumentsarerare.

ainedandhasnoexternalresis-

rrentflowingthroughthe instruments

ed,theneedleshould indicatezero.

ouldbecorrectedbymeansof thezero

NTSWITCHES

ngcontactsoftheammeterswitch.

dwithodd'numbersontheleft andeven

sideof theswitch,backview,starting

panel.Ifforany reasonacontactis

gnumberisalsoomitted;forinstance,

ft-handcontactofstage1;ifforany

ted,thenumberingwillstart with2

dcontactofstage1. Withthissystem

numberalsoidentifiesthestage;for

eft-handcontactofstage5, unless,

specialnumberingof contactsdueto


/ h t t p : / / w w w . h





SWITCHROARD

omtherearsupport.Putthe tie

ortand placeitonthetable withthe

he shaftintherear supportinan

ndingtotheverticalswitchposition,

rrangementonthedrawing.Assemble

ts.PlacetheC camfortherear

exactpositionshowninthecam

amandtheA.camlast. Continuewith

e samemanneruntilallthestages

theindentwheelorspringstretcherand

justenoughtoreplacethepin which

the indentwheelorspringstretcher.

tandifit isasustainedcontact

springwhichengagethenotchesin

mbledbeforepushingthefront support

first makingsurethebarriersare

SWITCHBOARD

nectionsoftheloadhavebeenmade,

ein offpositionwhenstartingthe

b toonposition,thatis,

hesafetystop controlismounted

erneaththecontrolpanel.SeeFigure

ntrolmarked"Stop"ispositioned

on.

d continuesfiring,releasethe

newill automaticallycomeuptofull

60cycleoperation.Assoonas theoil

l pressuregauge,theknobonthe

wtheswitchboardcabinetwillautomat-

rdposition.Thispositionwillpermit

ineincaseofno oilpressureorhigh

ratureislow,it willbedesirable

m1000to1200R.P.M.untilthe water

or120°.Thismaybe donebyholding

buttonand watchingthetachometer

peedismaintained.

ON


/ h t t p : / / w w w . h





/ h t t p : / / w w w . h





SET

peratedatno-loadfor approxi-

eengineandmakethe necessaryelec-

makeconnectionwithgeneratorrunning.

toryareconnectedfor60 cycle

LEADS

nnections,refertotheWiring

amisattachedtothe insideofthe

coverandisalsoshownin Figure320

eloadto terminalsmarked1,2,3,

ATORSET

cuitbreakeris inoffposition.

din paragraph190andpermitthe

mal.

atorknobforapproximately220

onthevoltmeter.

ostatso thatthepointer

rontofthepanel.See Figure316.

perateunderload.Withthe load

ertothe"On"position.

onnectedtotheexternalcircuit,

astheload isapplied.Theammeter

nedtoeachof itsthreepositionsto

ase.If singlephaseloadsarecon-

adjustedin orderthateachphase

ble.Thisswitchshouldbe leftin

highercurrent.

ldnotbecalleduponto deliver

ton onephaseeventhoughtheother

.

dedwithasafetyswitchlock

oardcabinet.Thisswitchprotectsthe

sureorhigh enginetemperature.

ttheswitchto functionproperly,the

ththe arrowpointingtotheleftfor

nginestartsandoilpressureregisters

uldautomaticallyturnin thedownward

eswitchto stoptheengineincase

ssureorhigh watertemperature.

N

esignedforparalleloperation

metypeandmodel.Whenparallel

entwogeneratorsets,itis necessary

.Forthispurpose,eachunithas a

N


/ h t t p : / / w w w . h





sandasynchronizingswitch.Load

nits tobeparalleledmustbe connected

tiontothesamebus.Theseconnec-

o1,2to 2,etc.Thefirstgenerator

escribedinparagraphs190and192for

onnectedtoload.Thesecondgenerator

speedanditsvoltageadjusted.Thefirst

redas therunningmachineandthesecond

eforestartingthe engineofthein-

eris inoffposition.Ontheincoming

witchshouldbeturnedtothe onposi-

chronizinglampswillbefoundtoflash

dependentuponthedifferenceofthe

edwhenthefrequencyoftheseflashes

lampsareout,ordark.Whenthis

wounitsmaybe connectedbyclosing

omingunit,afterwhichthetwounits

dentthat theessentialneces-

ngisthetimeof theclosingofthe

oltagesareslightlyapart,smallcross

themachineswithnodetrimentto the

oltagevariation,ifany,in theload

sedisplacementexistsatthetime

e incomingmachinebyreasonofclos-

ase,more orlessseverejoltswill be

ha littleexperienceandcare,the

thebreakerclosingmovementwiththe

agesthatthebreakercanbeclosed

enapplied,turntheknobonthe

hunitshowsthesame currentonthe

erreadings,makesurethatthephaseon

onthe samephase,asindicatedby

rethattheengine stopbuttonis,pushed

onizinghasbeenmade.

sarytoadjustthegovernorfor

kecertainthatallunitstobe synchro-

dsandvoltageat noload.Inmakingthis

orsetstooperateuntilthe temperature

hesame.Althoughthetachometeron

perationatthe speedindicated,this

ughforsynchronizing.Inorderto

permittheunitstooperateatno load

theload busandthesynchronizing

eon position.Thiswillpermitthe

etherelativespeedsofeachunit.

tno load,thesynchronizinglights

djustthegovernor,ifnecessary,on

67


/ h t t p : / / w w w . h





tingScrew

onditionisobtained.Toadjust

cknutontheadjustingscrewat the

ownin Figure321.Adjustthisscrew

zationisobtained.Seeparagraph65.

RALLELOPERATION

nnectoneunit(generatorset)

noperatingparallelwithotherunits,

s firstopenedbeforeattempting

tyinterlockisprovidedonthegov-

the governorleverwhenthestopbutton

hisprovisionismadein orderto

ris openwhentheengineisstopped.

N

egeneratorseton 50cycles,

ovethe100A.thermalelementinthe

allthe spare50A.thermalelement

ht sideofthecontrolcover.

EMOVINGTRIPPINGELEMENTOFAIRCIRCUIT

ateonpanel.Removethefour

coverandremovecover.Thenremove

ythetwoholdingscrewsandpass under-

It willhangbyits twoexternal

Removethethreeleadholdingscrews

fthebreaker.Removethebreaker

sethetripelementslightly soasto

mthebreakerandremove.


/ h t t p : / / w w w . h





ION

nedtoa rightsidecoverand,

theunusedelementshouldbeboltedto

ebreakerfromtheunit, leads

theback,theundervoltageleadsdis-

nfromtheirclips,andthefrontcover

ovethefourrearholdingscrewswhich

upports.

vablehandle,careshouldbetaken

tion"lineisatthe bottomorthe

dle,is rightsideup.

thefront coverofthebreakers

ytightenedto avoidstrains.Itis

gressivelytightenedasonewould

arwheel.Thesteelcoveronthe

edto giveanequalclearancebetween

foretightening.

THE60CYCLETO50CYCLEOPERATION(After

95havebeenfollowed.)

ontheterminalbox locatedon

terminalboardinlinewiththe

hedtotheterminalbox,or seeFigure

overfromthevoltageregulator.

inalonthe smallresistoratthelower

itionmarked50cycles.

romtheswitchboardcabinetami

a guide,reconnectwiresmarked"A",

as showninthemarginalinformation.

the tapperrighthandcornerof

ngtothe instructionsinpara-

thatthecircuitbreakeris inoff

espeedadjusting screwatthe

ownin Figure307.Loosenthisscrew

t1500 R.P.M.atnoload.Seepara-

etshouldnow bereadytooperateon

Allcoversshouldbereplacedand

ONS

o"Offposition.Pullstop con-

nginetoidlea fewminutes,after

all thewayouttostop theengine.


/ h t t p : / / w w w . h





TORSET

TORSET

BLY

semblyarerecommended:

oximately18"fromthefloor.

egeneratorliftingeye,liftthe genera-

he approximatepositiontoassemble

ouplingflangemustgo intothefly-

thegeneratorframeslipsintothe

heelhousing.SeeFigure104'.

wheelcapscrewsandalsothe

eatorcapscrewsbeforetighteningany

entheflywheel-to-generatorcapscrews

pling-to-flywheelcapscrews.SeeFigure

neratorassembledasaunit,lift

ame.Themountingframeshouldhave

edtothe frameandtheflexiblemount-

ngineandgeneratoraresetin place.

mountingboltsandthe twomounting

otor.

s,and braces.

trolunit frame.

ntroluniton theframe.

softheengine controlsanden-

thegenerator.

ontrolon theframeandconnect

e WiringDiagram,Figure320.

eneratorcircuitbreaker,switch

gure102 andhookitupaccordingto

e320.

ycontrolswitchand hookit

shut offvalveaccordingtothe

hand hookuptheenginewiring

ngtotheengineWiring Diagram,Figure

ATORFORTESTRUN

enquartsofthe recommended

ordingtothe operatingtemperature.

ON


/ h t t p : / / w w w . h





TORSET

t,cleanwaterorsuitable

rter motor.

mphousingwithclean,fresh

elmarkandalso fillthegovernor

hefulllevel mark.

lineto thefirststage,orpri-

nnectiononthefueltank.NOTE:The

fueltankisthe specialplugwhichhas

ottomof thetank.Connectthefuel

97.

ne fromthefuelinjection

eturnopening.See Figure197.NOTE:

gshouldbe connectedtothehorizontal

oneofthefueltank connections,

s "T"shouldbeprovidedwithan

gpurposes.

ofthe fuelinjectionpumpto

kvalvespringtensionsopumphousing

efuel

e322

e

out

ns

ustbe

eft)

n-

he

el

he

the

e

oximately900R.P.H.)andcheckfor

ringthe engineuptonormaloperat-

atertemperaturerisesto 100° or120°.

overandadjustthevalvetappets

ows:Theintakeclearanceshouldbe

2".Insertthecorrectfeelergauge

ndthevalvestem.SeeFigure 323.

ugebackandforth.If theclearanceis


/ h t t p : / / w w w . h





/ h t t p : / / w w w . h





TORSET

otethatthereis justaslightdrag

hmomentarilypreventshimfrommoving

ranceis notcorrect,thiswillbe

chwillnotpermitthe feelergaugeto

bledrag.Ontheotherhand,if the

utanybinding,theclearanceisIn-

teighthoursasfollows:(a)

R.P.M.;(b)twohoursnoloadat 1800

fload;(d) twohoursat3/4load.

sforobtainingloads.

turesafetyswitchbyraisingthe

byclosingoffthe aircirculation

newillstopa fewminutesafterthe

°.Seeparagraph115.

sarytoadjustthesmokestop in

dthereis noothermeanstohookup

he waterbarrelmethodofcreating

ewaterbarrelmethodis asfollows:

waterand addsalt.Obtain

nd attachtoeachofthethree phase

tothewater barrelapproximately12"

equidistantinordertobalancethe

essaryload,voltstimesamperes,times

vethedesiredkilowatts.Forin-

s 36K.W.,thevoltmetershould

94-1/2,or iftheloaddesiredis 35

dread220andthe ammeter92.For30

dread220andthe ammeterread79.An

eloadcan beobtainedbyloweringor

thewaterbarrel.

nthetachometerforthe critical

.M.thatarenecessary,butuseacounter

encymeter.Thesetting atthefactory

0to 61.5cyclesfor1800and1845

CTIONPUMP

umpwith theengine,thefollow-

to timethefuelinjectionpump

e timingmarkNo.1,F.P.I.

inthecenterofthe timingholeof

Figure190.NOTE:TheNo.1 piston

ionstrokewhencenteringthistimingmark

ywheelhousing.Thiscanbechecked

73


/ h t t p : / / w w w . h





TORSET

akeandexhaustvalvesofNo.1cyl-

edandhaveclearancebetweenthesten

diator.Removetheoil filler

romthecapscrewsofthefuel

thethreecapscrewssothatthe gear

ure324.

edi-

ub.

of

he

i-

-

e

k

ub

s

er

he

eNo.

c-

the

26.

n

he

ns-

-

the

e

ar

es

n

ng.


/ h t t p : / / w w w . h





TORSET

n

7,

ge

he

ked

moment

anbe

e

nk-

he

-

hole

is

ct

re190. Ifnotthetiming iseither

etimingis advanced,thetimingmark

thecenterof theflywheelhousing

emarkhas gonepast.

etimingis retarded,loosen

huband turnthehubclockwise(as

egreemark.If timingisadvanced,the

counter-clockwiseonedegreemark.

ubcounter-clockwise,asshownin

he hubretainingnut.Exertjust

enchhandletomovethe hub.Tighten

kthetimingbeginningwithStep6.It

attheforegoingproceduremorethanonce

diatelyuponportclosingwhich

dcenterofNo. 1cylinder,asmeasured

dNo.1 F.P.I.^

age

mp)


/ h t t p : / / w w w . h





beenfilled withdirtdueto dust

nditions,orhas beensubmergedduring

hwaterand iscloggedwithmud

bablyrequirea thoroughwashingout,

etear-downoftheentire unit.

MENTOFENGINEAFTERSUBMERSIONINSALTOR

heengineisrequired,and unfor-

ntforthisoperationisrarelyavailable

.Thisbrings intheelementoftime.

betakentopreventcorrosion,inso far

whentheengineiscompletelydis-

aned.Theactionoftheair creates

llpartsofthe engineshouldbecoated

withoil topreventtheairreaching

attheairbe keptfromcontacting

caseswhereoilisnot available,

lowtheenginetoremainunderwater

mcanbeobtained,provided,ofcourse,

inareasonablelengthoftime.

egivento theimportanceofworking

attheengineisto besalvaged.

mustbepromptlymadetodismantlethe

bleandthoroughlycleanand slush

ccurredinsaltwater,it isrecom-

e engineisdismantled,allpartsother

bewashedinhotfreshwater,dried,

goilthat hasbeenheatedto180° F.

ries,suchasstartermotorandgenera-

ushedwithfreshwater,dried and

eforeusing.Whentheseelectricalen-

overhauled,theyshouldbevisually

on,theconditionofallinsulation

calcircuitsthoroughlytestedbe-

gtctheinstructionsgiveninpara-

65. Allwindingsthatareotherwise

edinanovenat 140° F.forfourhours

xibleconduitsmustbereplaced.

bemadeofeachpart salvagedto

entofthe damagescausedbycorrosion

sedbythe suddencoolingactionofthe

nginewasat operatingtemperatureat

ersion.

MENTOFGENERATOR

hhasbeenfilledwithdirtby dust

nditionsorhas beensubmergedduring

hmudandforeignmatterwillrequire

ON


/ h t t p : / / w w w . h





suchcases,disassembletheapparatus

rtswithwater.Use anapprovedsolvent

insulation.If waterisappliedto

,the pressureshouldnotexceed25

RATOR

sulationinclude:wipingoffthe

,blowingitoutwithair pressure,

pparatus,removingit invarious

ashingitoutwith water—sometimeshot

eeded.Themethodwill,ofcourse,

sinvolved.

DAIR

tabout25poundspressureis

arlywhenthedirthascollectedin

achedwithacloth.Donot directcom-

onuntilcertainthat itisfree

veaccumulatedintheairline from

nairpressuremayloosenbindingtape

blownoutofa machineislikelyto

re inoperationnearit.Remember

implytransfersthe dirtfromone

essthefinal locationisoutside

ttlegoodhaybe accomplished.

ontainsoil orgrease,asolvent

t. Therearethreetypesofsolvents

e.

ates,suchasbenzineor gasoline,

ichareextremelytoxic)carbontetra-

hetwo.

eleast corrosiveactiononthe

orthatreason,whereconditionspermit,

solvents.Benzine,havinga flash

sperhapsthe mostgenerallydesir-

merciallyasStoddardSolvents(described

dsas"CommercialStandardSC-3-28"),

etyTypeSolventsminimizethefire

n preferencetogasolineorbenzine,

ouldbeusedto preventfiresorexplo-

rbontetrachlorideand50%benzineor

and40%gasolineisnotinflammable,

he rightproportionofairare explo-

,solventsare generallyused

thclothsmoistenedwiththe clean-

77


/ h t t p : / / w w w . h





solventmaybesprayedonthein-

rtsmay bedippedintothesolvent.

sareused,guardcarefully

areveryinflammableand

yexplosivewhenmixedwiththeproper

tilationandminimumfirerisk.

becomesaturatedwiththe

uldbecomesaturated,itshouldbe

herhandy.

ingmetalparts ofthegen-

uldnothaveprotrudingnails.

hercleaningsolutionor

enozzleis grounded.

hloride,guardagainstbreath-

uldbeprovidedwhenanytype

ethodsofdryingthe insulationof

ternalheat,andacombinationof

s,wherepossible,istodrythe gen-

ehot.

NALHEAT

generatorwith electricheaters

ofthe windingiseffective.Most

darethespaceheaters.Thistype of

wide,anddependingupontheir capa-

2"to43"long.

recommended.Agoodtemporary

elsof heatinsulatingmaterialsecured

anbe madeofsheetiron,bricks,or

insulatingmaterial.

ventilatedtoprovideair circu-

ure.Pre-heatedairmaybe forced

ndsofheatersmaybe usedifprecau-

ON


/ h t t p : / / w w w . h





nd tokeeptheactualproductof

LHEAT

dried bycirculatingcurrent

way,internalheatcanbedeveloped

ontovoltagesthatmight damage

aysdanger,however,ofserious

rying theinsulationinthismanner

he innerpartsisnot readilydissi-

ningmoisturearemostsusceptible

asesandvaporsgeneratedwithin

suchpressurethattheyare forced

kingthecontinuityofthelayers or

meansofdrying shouldbecarefully

duntiltheinsulationr esistance

andthenhasincreaseduntilat least

volts,operatingvoltage,isindicated,

megohm,regardlessofvoltage.It

intainthetemperatureatfrom15to

ady foroperation.

enerators,theinternalheat

ebytheshortcircuitmethodor low

rce.Theshortcircuitmethodmeans

ewindingsanddrivingthe generator

excitationtogivesomewhatless

ent.Whenthe windingsareprovided

edetectorsorwhentemperaturesare

ofresistancemethod,thecurrentmay

ternal temperatureof85° C.from

un. Ifthetemperatureindications

meterslocatedontheoutsideofthe high

ralhoursmayelapsebeforemaximum

ntcurrent,ventilation,andambient

indicated.Sincethesetemperatures

owerthanthetemperaturesatthe

C.

roman externalsourcefordrying

ntmustbe controlledsoasnotto

Whenalternatingcurrentis sup-

n externalsource,thefieldwindings

ited.

79


/ h t t p : / / w w w . h





/ h t t p : / / w w w . h





,30KW

ATORSET

ntract56995

sandInstructions402-3

emblies404-5

ngineAssemblies407-422

Accessories423

es423-431

mAccessories432-438

ories'.439-440

cessories441

eneratorandExciterAssemblies...442-450

rIllustratingParts451

blies452-456

Parts457-461

tsandPrices462


/ h t t p : / / w w w . h





SITIONS

THE PREPARATIONOFREQUISITIONS

forrequisitioningspore porti

nheadings.Untilnew formsore

aretocontinueusingthe present

iteincorrectionsindicatedin column

omenclatureandUnit"listthe

each;Ibfor pound,etc.).Under

ximumLevel"listtheauthorized

izationalallowancesgiveninPart

rsSupplyCatalog.Thetotalnumber

tedunder"On Hand".Incolumn

byuseofone ofthefollowingterms:

ionofauthorizedallowances.

ubsequentrequisitionstomaintain

nsfornecessaryrepairsnotcovered

otal quantitypreviouslyrequisi-

or"Initial"and "Replenishment'

equired","DueIn",and"OnHand"

edorMaximumLevel".

mplerequisitiononQMCForm

the latestrevisions.Themarginal

preparinga requisitionforspare

ent.Additionalinformationonthis

on AA-]ofPartIII EngineerSupply

eEngineerFieldMaintenanceOffice,

Ohio.

pper

tion.

TERDEPOT,COLUMBUS,OHIO

>«i«AugUB-t1€,--1-84S.........*•"•4.....-3PECXAL......-------

TYQFFICERJ...EJffi.SAMP.J..HBi.XOBK..-..........._ .........

SUPPLYOFFICER,802ndENGINEERSBATTALION,

FICER

ATORiET_._J

pteml

ry^

chastoolsmustbeaccountedfor, whenrequisitioned,byastate-

placedon REPORTOFSURVEYorSTATEMENTOFCHARGES.

ntbytelephone,telegraph,orradiomustalwaysbeconfirmed

onmarked:"Confirming(stateidentifyingdata)."


/ h t t p : / / w w w . h





TIONS

correctformfor submissionbytheEngineer

ntheoppositepage.

DINMAKINGOUTREQUISITIONS.

ationofwork.PropertyOfficersmayauthorize

uisitionsinfinalform,leavingrequisitionnumber

yPropertyOfficer.

LLBEOBSERVEDCAREFULLYINPREPARING

PARTS:

tionforeachdifferentmachine.

pperrighthandcornerofrequisitionform.

byuseofoneof thefollowingterms:

tionofauthorizedallowances.

bsequentrequisitionstomaintainauthorized

nsfornecessaryrepairsnotcoveredbyallow-

structions.

eofmachine,andmake,model,serialnumber

ddatedeliveryis required,immediatelybelow

rgroupheadingsas showninmanufacturers'

snumbersandnomenclaturedescriptionsaccur-

otuseabbreviations.

ms.

entbytelephone,telegraph,orradiomustalways

ywithrequisitionmarked:"Confirming(state

stbeaccountedfor.


/ h t t p : / / w w w . h





ngineParts


/ h t t p : / / w w w . h





ushAssembly446

dSupport446

ockAssembly407

ock,SleevetandBearings408

409

l,TubesandStuds412

ValveSprings411

nections456

verGuard458

nMountingBase459

ments455

Generator434-435

olenoidSafetyShut-OffValve432-433

ly447

okeAssembly...448

47

kets414

9

usingGroup414

Connections423

rnLines431

ve425-426

415

lFiller415

Adaptor417

ndInstruments,452-454

er442-443

lTankConnections460

ets416

14

rossSectionofMainGenerator.450

dAssemblies418

9

20

erator)445

ElectricAlternator431

nerator)444

tionBoxAssembly449

HoseConnections439

Cover421

butor,HoseConnections420


/ h t t p : / / w w w . h





gineParts

)-»O^

sto rightofdividingline)

ERBLOCKASSEMBLY

ntainedinassemblyshownonpage 408)


/ h t t p : / / w w w . h





ngineParts


/ h t t p : / / w w w . h





ngineParts

0

AKDGASKET

D


/ h t t p : / / w w w . h





ngineParts

93Flange(1)

21Lockwasher(3)

GASKET

LVE

LHOUSINGGROUP


/ h t t p : / / w w w . h





ngineParts

2)

)

)

NDOILFILLER

KETS


/ h t t p : / / w w w . h





gineParts

4)

w(2)

)

ASKETS


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ngineParts


/ h t t p : / / w w w . h





ngineParti


/ h t t p : / / w w w . h





ngineParts

DISTRIBUTORHOSECONNECTIONS


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ngineParts


/ h t t p : / / w w w . h





ngineParts

DCONNECTIONS


/ h t t p : / / w w w . h





ngineParts


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gineParts

rgroundwirBj

orswitchwire

(4)

27

LORSOLENOIDSAFETYSHUT-OFFVALVE


/ h t t p : / / w w w . h





ngineParts

ENOIDSAFETYSHUT-OFFVALVE


/ h t t p : / / w w w . h





ngineParts

06326Capscrew(2)

GING)GENERATOR


/ h t t p : / / w w w . h





ngineParts

NE(BATTERYCHARGING)GENERATOR

10AisshownInplace.

mblyisIllustratedon page438)


/ h t t p : / / w w w . h





ngineParts

BLYNO.DE-56518)


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ngineParts

RTERMOTORSHOWNABOVE


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ngineParts

20V

TAGEREGULATOR


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ngineParts

LT

NG


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ngineParts


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rmineParts


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ngineParts


/ h t t p : / / w w w . h





XTOCROSS-SECTIONDRAWINGSHOWINGLOCATIONOFVARIOI

TRICTYPEARC-444ALTERNATOR

ingNo.Illustrated onP.

...............................ARC440300T445

.....E4595445

embly____ F3771-Gr3AAt

...............!.!loMI A445

qe..................E4907

ilAssembly..............'..'.',...06412Gr1

Front)..............F3283442

crow(Vi-ISxVje)____ ..'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.C2353-94A442

....C2O4O3E4595AA*

Front)NewDeparture.'.'..'.'.'.'.'.'.'.'.'.'.'.'.'.3310"445

torleads....................C19138

Lock Nut......................C15832445

eSlinqer.....................''C15833445

Lock NutWasherW10445

Nipple(2'/z'length) >/f.........'.'.'..' .''.F3771-43446

e..........B673044A

Ell(Std. 90°)'/.'.......'..F3771-44446

........B567I44A

olingStd.i/i' ..........'..'.'.'.'.'.'.'.'.'.'.'.'.'.'.44?

olt.........D2540443

Only(1 set)...........................16240-A444

Leads ......................C19671

Nut(10-32x1*)........................C2386-496E

Spring...........R0085-R008744A

Assembly.....R0085Or144*

x* f«)Not.............................AYES8860446

StudWasher......................"."C15437446

oort.............................C19131446

Term.Lug...........2064446

StudJamNut..........C2286-40A446

Stud..............................."...C19133446

BearingCap..............D6087445

Cap— CapScrew(s/j«-18x2:J4)...........C2346-20A442

CapScrew LackwosherC'i'e)............C2291A-21449

Cover...........D616744?

CoverScrew(H-16x'/i|Fll.Hd ..........C2364-228442

et................CT2278

y......E4971447

mbly.........../„

PoleAssembly'("4140Or.3 447

nly .......[„

PoletCollCompleteD1999-B447

ke..............................E3714448

keLocklnqScrew ____ C2387-506448

keAssembly... NO277443

Nat.676..................,...'.'.'.'.'.'.'.ES9702448

rinq................NO279448

mutator...............................DN91300A-Gr.6447

pletewithwinding)....................D6503-Gr2447

.............................C20856447

ont)................F3853442

ver.....................'C7702442

verScrew(V4-20x%)Rd.Hd..' '.'.'.'.C2386-497442

asePlug ('/•").........B5671446

ewLock Washer('/,}(Pc.22)..C2291A-22 449

ew(Vi-lOxH')Fll. Hd..................C2360-188442

p.................B3349

earinaCao..............,..,........,,C15848447

ubleShield) ........................SFF204447

ainer..............C16735447

Bolt...................Cl1518-5602442

H') Hex.Hd..........................'.C2286-38'442

Nutfor AlternatorLeads.........'......C2348-1847

Fan................D6438447


/ h t t p : / / w w w . h





TUX1KLt'CTRICALTKRNATOK

ARTNUMBERS


/ h t t p : / / w w w . h





TOCBOU.UCTIONDRAWINGSHOWINGLOCATIONOFVARIO

wirnouonm* tap„

hmite)6106449

32x%C2386-496449

D6477449

to>)D6475449

shlnq-RO227RO227-16

mite)16355

b(Ohmite)5104


/ h t t p : / / w w w . h





ngineParts

TURYELECTRICALTtiRNATOR

ARTNUMBERS


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ngineParts


/ h t t p : / / w w w . h





ngineParts

OLSANDINSTRUMENTS


/ h t t p : / / w w w . h





ngineParts


/ h t t p : / / w w w . h





ngineParts

Cable(2)DP2682-Caole111

CONNECTIONS


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ngineParts

-LOCKWASHER(6)

NG

)37"LONG


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ngineParts

>

NSCOVERGUARD


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ngineParts


/ h t t p : / / w w w . h





gineParts

rC61106267-Woiher161

Wrench-(l)10"A

-Socket-(1)13/16"


/ h t t p : / / w w w . h





ngineParts

0KWDieselGeneratorSet

30TO15708

ttabulatednumerically,thenalphabeticallybythe

esignation!.

mpleteaspossibleatthetimeof printing.Anumberofweightsofmanyof theparts

ationwasnotsuppliedbytheaccessorymanufacturer.Allpartslistedaremanu-

udaunlessotherwiseindicated.Tosavespacethesymbolof theaccessory

sfollows:

p.,Toledo,Ohio

p.,Springfield,Mao.

St.Louis,Mo.

aul,Minn.

Bridgeport,Conn.

o.,Chicago,III.

hCo.,Goshen,Indiana

derson,Ind.

p.,Chicago,III.

Inc.,Kingston,N.Y.

Racine,Wise.

ePolewith50-

ePolewith100-

452-4541

CE-24Ammeter

GE

K-6173199-G1

604GE

gs,rectifierand

Regulator....GE


/ h t t p : / / w w w . h





ngineParts

eReq.Lbs.

AL4383

rAL4368

1

s420120/per

O4273

rAL4351300/per

BO4271

O4272

4271

orAL4352300/per

arterAL4361

L4378

mpBO426

ratorAL4355000/per

eratorAL4351100/per

neratorAL43560per

RCUITBREAKERS.GE453

nzeAL437

435175/per

orAL4382

371750/per

371450/per

371200/per

ber,Vt"4202200/per

240/per

otorAL4371

rAL4364

5225/per

,'/4-Vi'420120/per

rAL4351650/per

yValvePES43220/per

435110/per

"pipe,threaded..4551000/per

35250/per

neratorAL4355000/per

8300/per

AL4372

nze,Generator....AL4351 35per

rAL4364

hHolderCE4464Vt

olderCE446 4160/per

olderCE446 440/per

RegulatorAL4382

egulator'... AL438

oltage,RegulatorAL438

VoltageRegulatorAL4382

WGB424'/•

dgeWGB441'/«

GB441H

24H

241

B4411

3V4

eOilFilterWGB4418

B4241 30/per

WGB4411 30/per

WGB4241200/per

verWGB4411 ISO/per

crewAL4372180/per

alStud,Voltage

tWGB42411


/ h t t p : / / w w w . h





ngineParts

egulator P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

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nginePart*

AL P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

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earingCap

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nginePorte

nly)CE

mpBO

eratorAL

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ngineParts

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ver,10— 32x:',fi".

derYokeLocking.

g,10— 32x%"...

mp,10—32x1".

ketCover,Vt"—

4'— 20x%*

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Front),NewDe-

CE

r

fValve(Gr.2

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se(std.)'/«"...

ePipe(2'/i")'/•".CE

sePipeCE

PieceCE

ont)CE

tingPG

I.P.S

sting

singDowel

arHousing

,1%,*

nRetainer

leCE

overStud(Lower)

eRegAL

oltageAL

T

ype

terAL

ng,BendixStarterAL

ng,BendixStarterAL

erCE

Bearing

CE

ceCE

y)CE

rterAL

d

rAL

gs(front)

g(rear)

stat(Ohmite)CE

L

ket

earingCap

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tGrease,'/«* CE


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nginePart*

E3


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ngineParts

mp

mp

p(OverflowValve).

mp

ump

gulator

V/{6")Nat.Ay...

p

76

upling,Hub,%"


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ngineParis

efValve

alve

zzle

eturnLines(1pr.)..

%"— 24Acorn..

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ontrol

over

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mpAdaptorPlateBO


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emperature


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mp

rmature

eet

"— 28x%"

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stingBrace(flat)

d i g i t i z e d

/ h t t p : / / w w w . h



Tm 5-5090 GENERATOR SET, BUDA

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Transcript of Tm 5-5090 GENERATOR SET, BUDA